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CROSS-REFERENCE TO A RELATED APPLICATION
[0001] This application is a continuation of U.S. Ser. No. 09/947,078, filed Sep. 5, 2001 which is a continuation of U.S. Ser. No. 09/484,706, filed Jan. 18, 2000 which claims the benefit of U.S. Provisional Application No. 60/160,710, filed Oct. 20, 1999.
FIELD OF THE INVENTION
[0002] The invention generally relates to a surgical method of intervertebral disc wall reconstruction with a related annulus stent augmenting the repair. The effects of said reconstruction are restoration of disc wall integrity and reduction of the failure rate (3-21%) of a common surgical procedure (disc fragment removal or discectomy). This surgical procedure is performed about 390,000 times annually in the United States.
BACKGROUND OF THE INVENTION
[0003] The spinal column is formed from a number of vertebrae, which in their normal state are separated from each other by cartilaginous intervertebral discs. The intervertebral disc acts in the spine as a crucial stabilizer, and as a mechanism for force distribution between the vertebral bodies. Without the disc,
[0004] The normal intervertebral disc has an outer ligamentous ring called the annulus surrounding the nucleus pulposus. The annulus binds the adjacent vertebrae together and is constituted of collagen fibers that are attached to the vertebrae and cross each other so that half of the individual fibers will tighten as the vertebrae are rotated in either direction, thus resisting twisting or torsional motion. The nucleus pulposus is constituted of loose tissue, having about 85% water content, which moves about during bending from front to back and from side to side.
[0005] As people age, the annulus tends to thicken, desicate, and become more rigid. The nucleus pulposus, in turn, becomes more viscous and less fluid and sometimes even dehydrates and contracts. The annulus also becomes susceptible to fracturing or fissuring. These fractures tend to occur all around the circumference of the annulus and can extend from both the outside of the annulus inwards, and the interior outward. Occasionally, a fissure from the outside of the annulus meets a fissure from the inside and results in a complete rent or tear through the annulus fibrosis. In situations like these, the nucleus pulposus may extrude out through the annulus wall. The extruded material, in turn, can impinge on the spinal cord or on the spinal nerve rootlet as it exits through the intervertebral disc foramen, resulting in a condition termed ruptured disc or herniated disc
[0006] In the event of annulus rupture, the inner-nucleus component migrates along the path of least resistance forcing the fissure to open further, allowing migration of the nucleus pulposus through the wall of the disc, with resultant nerve compression and leakage of chemicals of inflammation into the space around the adjacent nerve roots supplying the extremities, bladder, bowel and genitalia. The usual effect of nerve compression and inflammation is intolerable back or neck pain, radiating into the extremities, with accompanying numbness, weakness, and in late stages, paralysis and muscle atrophy, and/or bladder and bowel incontinence. Additionally, injury, disease or other degenerative disorders may cause one or more of the intervertebral discs to shrink, collapse, deteriorate or become displaced, herniated, or otherwise damaged.
[0007] The surgical standard of care for treatment of herniated, displaced or ruptured intervertebral discs is fragment removal and nerve decompression without a requirement to reconstruct the annular wall. While results are currently acceptable, they are not optimal. Various authors report 3.1-21% recurrent disc herniation, representing a failure of the primary procedure and requiring re-operation for the same condition. An estimated 10% recurrence rate results in 39,000 re-operations in the United States each year.
[0008] An additional method of relieving the symptoms is thermal annuloplasty, involving the heating of sub-annular zones in the non-herniated painful disc, seeking pain relief, but making no claim of reconstruction of the ruptured, discontinuous annulus wall.
[0009] There is currently no known method of annulus reconstruction, either primarily or augmented with an annulus stent.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention provides methods and related materials for reconstruction of the disk wall in cases of displaced, herniated, ruptured, or otherwise damaged intervertebral discs.
[0011] In a preferred form, one or more mild biodegradable surgical sutures are placed at about equal distances along the sides of a pathologic aperture in the ruptured disc wall (annulus) or along the sides of a surgical incision in the weakened, thinned disc annulus.
[0012] Sutures are then tied in such fashion as to draw together the sides of the aperture, effecting reapproximation or closure of the opening, to enhance natural healing and subsequent reconstruction by natural tissue (fibroblasts) crossing the now surgically narrowed gap in the disc annulus.
[0013] A 25-30% reduction in the rate of recurrence of disc nucleus herniation through this aperture, has been achieved using this method.
[0014] In another embodiment, the method can be augmented by placement of a patch of human muscle fascia (the membrane covering the muscle) or any other autograft or allograft acting as a bridge in and across the aperture, providing a platform for traverse of fibroblasts or other normal cells of repair existing in and around the various layers of the disc annulus, prior to closure of the aperture.
[0015] A 30-50% reduction in the rate of recurrence of disc herniation has been achieved using the aforementioned fascial augmentation with this embodiment.
[0016] Having demonstrated that human muscle fascia is adaptable for annular reconstruction, other biocompatible membranes can be employed as a bridge, stent, patch or barrier to subsequent migration of the disc nucleus through the aperture. Such biocompatible materials may be, for example, a medical grade biocompatible fabric, biodegradable polymeric sheets, or form fitting or non-form fitting fillers for the cavity created by removal of a portion of the disc nucleus in the course of the disc fragment removal or discectomy. The prosthetic material can be placed in and around the intervertebral space, created by removal of the degenerated disc fragments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 shows a perspective view of the annulus stent.
[0018] [0018]FIG. 2 shows a front view of the annulus stent.
[0019] [0019]FIG. 3 shows a side view of the annulus stent.
[0020] FIGS. 4 A- 4 C show a front view of various alternative embodiments of the annulus stent.
[0021] FIGS. 5 A- 5 B shows the alternative embodiment of a pyramid shaped annulus stent.
[0022] FIGS. 6 A- 6 B shows the alternative embodiment of a coned shaped annulus stent.
[0023] [0023]FIG. 7 shows the primary closure of the opening in the disc annulus, without an intervertebral or subannular stent.
[0024] FIGS. 8 A- 8 B shows the primary closure with a stent in generic form.
[0025] [0025]FIG. 9 shows a method of suturing the annulus stent into the disc annulus, utilizing sub-annular fixation points.
[0026] FIGS. 10 A- 10 B show the annulus stent with flexible bladder being expanded into the disc annulus.
[0027] FIGS. 11 A- 11 D show the annulus stent being inserted into the disc annulus.
[0028] FIGS. 12 A- 12 B show the annulus stent with the flexible bladder being expanded by injection.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The present invention provides methods and related materials for reconstruction of the disk wall in cases of displaced, herniated, ruptured, or otherwise damaged intervertebral discs.
[0030] In one embodiment of the present invention, as shown in FIG. 7, a damaged annulus 42 is repaired by use of surgical sutures 40 . One or more surgical sutures 40 are placed at about equal distances along the sides of a pathologic aperture 44 in the ruptured annulus 42 . Reapproximation or closure of the aperture 44 is accomplished by tying the sutures 40 in such a fashion that the sides of the aperture 44 are drawn together. The reapproximation or closure of the aperture 44 enhances the natural healing and subsequent reconstruction by the natural tissue crossing the now surgically narrowed gap in the annulus 42 . Preferably, the surgical sutures 40 are biodegradable, but permanent non-biodegradable may be utilized.
[0031] Additionally, to repair a weakened or thinned disc annulus 42 , a surgical incision is made along the weakened or thinned region of the annulus 42 and one or more surgical sutures 40 are placed at about equal distances along the sides of the incision. Reapproximation or closure of the incision is accomplished by tying the sutures 40 in such a fashion that the sides of the incision are drawn together. The reapproximation or closure of the incision enhances the natural healing and subsequent reconstruction by the natural tissue crossing the now surgically narrowed gap in the annulus 42 . Preferably, the surgical sutures 40 are biodegradable, but permanent non-biodegradable materials may be utilized.
[0032] In an alternative embodiment, the method can be augmented by the placement of a patch of human muscle fascia or any other autograft, allograft or xenograft in and across the aperture 44 . The patch acts as a bridge in and across the aperture, providing a platform for traverse of fibroblasts or other normal cells of repair existing in and around the various layers of the disc annulus, prior to closure of the aperture.
[0033] In a further embodiment, as shown in FIG. 8, a biocompatible membrane can be employed as an annulus stent 10 , being placed in and across the aperture 44 . The annulus stent 10 acts as a bridge in and across the aperture 44 , providing a platform for a traverse of fibroblasts or other normal cells of repair existing in and around the various layers of the disc annulus, prior to closure of the aperture 44 .
[0034] In a preferred embodiment, as shown in FIGS. 1 - 3 , the annulus stent 10 comprises a centralized vertical extension 12 , with an upper section 14 and a lower section 16 . The centralized vertical extension 12 can be trapezoid in shape through the width and may be from about 8 mm-12 mm in length.
[0035] Additionally, the upper section 14 of the centralized vertical extension 12 may be any number of different shapes, as shown in FIGS. 4A and 4B, with the sides of the upper section 14 being curved or with the upper section 14 being circular in shape. Furthermore, the annulus stent 10 may contain a recess between the upper section 14 and the lower section 16 , enabling the annulus stent 10 to form a compatible fit with the edges of the aperture 44 .
[0036] The upper section 14 of the centralized vertical extension 12 can comprise a slot 18 , where the slot 18 forms an orifice through the upper section 14 . The slot 18 is positioned within the upper section such that 14 it traverses the upper section's 14 longitudinal axis. The slot 18 is of such a size and shape that sutures, tension bands, staples or any other type of fixation device known in the art may be passed through, to affix the annulus stent 10 to the disc annulus 44 .
[0037] In an alternative embodiment, the upper section 14 of the centralized vertical extension 12 may be perforated. The perforated upper section 14 contains a plurality of holes which traverse the upper section's 14 longitudinal axis. The perforations are of such a size and shape that sutures, tension bands, staples or any other type of fixation device known in the art may be passed through, to affix the annulus stent 10 to the disc annulus 44 .
[0038] The lower section 16 can comprise a pair of lateral extensions, a left lateral extension 20 and a right lateral extension 22 . The lateral extensions 20 and 22 comprise an inside edge 24 , an outside edge 26 , an upper surface 28 , and a lower surface 30 . The lateral extensions 20 and 22 can have an essentially constant thickness throughout. The inside edge 24 is attached to the lower section 16 and is about the same length as the lower section 16 . The outside edge 26 can be about 8 mm-16 mm in length. The inside edge 24 and the lower section 16 meet to form a horizontal plane, essentially perpendicular to the centralized vertical extension 12 . The upper surface 28 of the lateral extensions 20 and 22 can form an angle of about 0°-60° below the horizontal plane. The width of the annulus stent 10 may be from about 3 mm-5 mm.
[0039] Additionally, the upper surface 28 of the lateral extensions 20 and 22 may be barbed for fixation to the inside surface of the disc annulus 40 and to resist expulsion through the aperture 44 .
[0040] In an alternative embodiment, as shown in FIG. 4B, the lateral extensions 20 and 22 have a greater thickness at the inside edge 24 than at the outside edge 26 .
[0041] In a preferred embodiment, the annulus stent 10 is a solid unit, formed from one or more of the flexible resilient biocompatible or bioresorbable materials well know in the art.
[0042] For example, the annulus stent may be made from:
[0043] a porous matrix or mesh of biocompatible and bioresorbable fibers acting as a scaffold to regenerate disc tissue and replace annulus fibrosus as disclosed in, for example, U.S. Pat. Nos. 5,108,438 (Stone) and 5,258,043 (Stone);
[0044] a strong network of inert fibers intermingled with a bioresorbable (or biosabsorable) material which attracts tissue ingrowth as disclosed in, for example, U.S. Pat. No. 4,904,260 (Ray et al.);
[0045] a biodegradable substrate as disclosed in, for example, U.S. Pat. No. 5,964,807 (Gan at al.); or
[0046] a expandable polytetrafluoroethylene (ePTFE), as used for conventional vascular grafts, such as those sold by W. L. Gore and Associates, Inc. under the trademarks GORE-TEX and PRECLUDE, or by Impra, Inc. under the trademark IMPRA.
[0047] Furthermore, the annulus stent 10 , may contain hygroscopic material for a controlled limited expansion of the annulus stent 10 to fill the evacuated disc space cavity.
[0048] Additionally, the annulus stent 10 may comprise materials to facilitate regeneration of disc tissue, such as bioactive silica-based materials which assist in regeneration of disc tissue as disclosed in U.S. Pat. No. 5,849,331 (Ducheyne, et al.), or other tissue growth factors well known in the art.
[0049] In further embodiments, as shown in FIGS. 5 - 6 , the left and right lateral extensions 20 and 22 join to form a solid pyramid or cone. Additionally, the left and right lateral extensions 20 and 22 may form a solid trapezoid, wedge, or bullet shape. The solid formation may be a solid biocompatible or bioresorbable flexible material, allowing the lateral extensions 20 and 22 to be compressed for insertion into aperture 44 , then to expand conforming to the shape of the annulus' 42 inner wall.
[0050] Alternatively, a compressible core may be attached to the lower surface 30 of the lateral extensions 20 and 22 , forming a pyramid, cone, trapezoid, wedge, or bullet shape. The compressible core may be made from one of the biocompatible or bioresorbable resilient foams well known in the art. The compressible core allows the lateral extensions 20 and 22 to be compressed for insertion into aperture 44 , then to expand conforming to the shape of the annulus' 42 inner wall and to the cavity created by pathologic extrusion or surgical removal of the disc fragment.
[0051] In a preferred method of use, as shown in FIGS. 10 A- 10 D, the lateral extensions 20 and 22 are compressed together for insertion into the aperture 44 of the disc annulus 40 . The annulus stent 10 is then inserted into the aperture 44 , where the lateral extensions 20 and 22 expand, with the upper surface 28 contouring to the inside surface of the disc annulus 40 . The upper section 14 is positioned within the aperture 44 so that the annulus stent 10 may be secured to the disc annulus 40 , using means well known in the art.
[0052] In an alternative method, where the length of the aperture 44 is less than the length of the outside edge 26 of the annulus stent 10 , the annulus stent 10 must be inserted laterally into the aperture 44 . The lateral extensions 20 and 22 are compressed, and the annulus stent 10 is laterally inserted into the aperture 44 . The annulus stent 10 is then rotated inside the disc annulus 40 , such that the upper section 14 is pulled back through the aperture 44 . The lateral extensions 20 and 22 are then allowed to expand, with the upper surface 28 contouring to the inside surface of the disc annulus 40 . The upper section 14 is positioned within the aperture 44 such that the annulus stent 10 may be secured to the disc annulus, using means well known in the art.
[0053] In an alternative method of securing the annulus stent 10 in the aperture 44 , as shown in FIG. 9, a first surgical screw 50 and second surgical screw 52 , with eye holes 53 located at the top of the screws 50 and 52 , are opposingly inserted into the adjacent vertebrae 54 and 56 below the annulus stent 10 . After insertion of the annulus stent 10 into the aperture 44 , a suture is passed down though the disc annulus 40 , adjacent to the aperture 44 , through the eye hole 53 on the first screw 50 then back up through the disc annulus 40 and through the orifice 18 on the annulus stent 10 . This is repeated for the second screw 52 , after which the suture is secured. One or more surgical sutures 40 are placed at about equal distances along the sides of the aperture 44 in the disc annulus 42 . Reapproximation or closure of the aperture 44 is accomplished by tying the sutures 40 in such a fashion that the sides of the aperture 44 are drawn together. The reapproximation or closure of the aperture 44 enhances the natural healing and subsequent reconstruction by the natural tissue crossing the now surgically narrowed gap in the annulus 42 . Preferably, the surgical sutures 40 are biodegradable but permanent nonbiodegradable forms may be utilized. This method should decrease the strain on the disc annulus 40 adjacent to the aperture 44 , precluding the tearing of the sutures through the disc annulus 40 .
[0054] It is anticipated that fibroblasts will engage the fibers of the polymer or fabric of the intervertebral disc stent, forming a strong wall duplicating the currently existing condition of healing seen in the normal reparative process.
[0055] In an additional embodiment, as shown in FIGS. 1 A-B, a flexible bladder 60 is attached to the lower surface 30 of the annulus stent 10 . The flexible bladder 60 comprises an internal cavity 62 surrounded by a membrane 64 , where the membrane 64 is made from a thin flexible biocompatible material. The flexible bladder 60 is attached to the lower surface 28 of the annulus stent 10 in an unexpanded condition. The flexible bladder 60 is expanded by injecting a biocompatible fluid or expansive foam, as known in the art, into the internal cavity 62 . The exact size of the flexible bladder 60 can be varied for different individuals. The typical size of an adult nucleus is 2 cm in the semi-minor axis, 4 cm in the semi-major axis and 1.2 cm in thickness.
[0056] In an alternative embodiment, the membrane 64 is made of a semi-permeable biocompatible material.
[0057] In a preferred embodiment, a hydrogel is injected into the internal cavity of the flexible bladder 28 . A hydrogel is a substance formed when an organic polymer (natural or synthetic) is cross-linked via covalent, ionic, or hydrogen bonds to create a three-dimensional open-lattice structure which entraps water molecules to form a gel. The hydrogel may be used in either the hydrated or dehydrated form.
[0058] In a method of use, where the annulus stent 10 has been inserted into the aperture, as has been previously described and shown in FIGS. 12 A- b , an injection instrument, as known in the art, such as a syringe, is used to inject the biocompatible fluid or expansive foam into the internal cavity 62 of the flexible bladder 60 . The biocompatible fluid or expansive foam is injected through the annulus stent 10 into the internal cavity of the flexible bladder 28 . Sufficient material is injected into the internal cavity 62 to expand the flexible bladder 60 to fill the void in the intervertebral disc cavity. The use of the flexible bladder 60 is particularly useful when it is required to remove all or part of the intervertebral disc nucleus.
[0059] The surgical repair of an intervertebral disc may require the removal of the entire disc nucleus, being replaced with an implant, or the removal of a portion of the disc nucleus thereby leaving a void in the intervertebral disc cavity. The flexible bladder 60 allows for the removal of only the damaged section of the disc nucleus, with the expanded flexible bladder 60 filling the resultant void in the intervertebral disc cavity. A major advantage of the annulus stent 10 with the flexible bladder 60 is that the incision area in the annulus can be reduced in size as there is no need for the insertion of an implant into the intervertebral disc cavity.
[0060] In an alternative method of use, a dehydrated hydrogel is injected into the internal cavity 28 of the flexible bladder 60 . Fluid, from the disc nucleus, passes through the semi-permeable membrane 64 hydrating the dehydrated hydrogel. As the hydrogel absorbs the fluid the flexible bladder expands 60 , filling the void in the intervertebral disc cavity.
[0061] All patents referred to or cited herein are incorporated by reference in their entirety to the extent they are not inconsistent with the explicit teachings of this specification, including; U.S. Pat. No. 5,108,438 (Stone), U.S. Pat. No. 5,258,043 (Stone), U.S. Pat. No. 4,904,260 (Ray et al.), U.S. Pat. No. 5,964,807 (Gan et al.), U.S. Pat. No. 5,849,331 (Ducheyne et al.), U.S. Pat. No. 5,122,154 (Rhodes), U.S. Pat. No. 5,204,106 (Schepers at al.), U.S. Pat. No. 5,888,220 (Felt et al.) and U.S. Pat. No. 5,376,120 (Sarver et al.).
[0062] It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and preview of this application and the scope of the appended claims. | A surgical method of repair and reconstruction of the spinal disc wall (annulus) after surgical invasion or pathologic rupture, incorporating suture closure, or stent insertion and fixation, designed to reduce the failure rate of conventional surgical procedures on the spinal discs.
The design of the spinal disc annulus stent allows ingrowth of normal cells of healing in an enhanced fashion strengthening the normal reparative process. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a safety lancet device, and more particularly to a safety lancet device for obtaining small blood samples, which mounts a new needle hub within the safety lancet device to obtain each blood sample.
2. Description of Related Art
To take small amounts of blood from the finger or the earlobe for diagnostic purposes, lancets are used to prick the corresponding body part either manually or with the aid of a simple apparatus. The lancet has to be sharp and sterile. However, if the force applied to the lancet is not large enough, the lancet will not prick the body part.
Furthermore, a conventional lancet device used for taking small amounts of blood is like a mechanical pencil. The conventional lancet device comprises a top thumb tab, a casing, a driver assembly and a needle hub with a needle. The top thumb tab, the driver assembly and the needle hub are mounted within the casing. The top thumb tab is attached on the driver assembly and the driver assembly is attached on the needle hub. After pressing the top thumb tab, the driver assembly forces the needle to protrude from the needle hub. However, the used needle hub of the conventional lancet device can continue to be use so users may forget to replace the used needle hub with a new needle hub. In which case, the used needle in the needle hub will prick the next patient. If the used needle is contaminated, the person may be infected.
SUMMARY OF THE INVENTION
The main objective of the present invention is to provide a safety lancet device that will necessitate that a new needle hub be installed before each use.
To achieve the objective, a safety lancet device in accordance with the present invention comprises a casing, a driver assembly and a needle hub with a needle. The driver assembly and the needle hub are mounted inside the casing. The driver assembly comprises a container, a pressing unit, a controller, a pushing unit and a resilient element. The pressing unit is mounted around the pressing unit. The controller is mounted in the container, and the pushing unit is mounted in the controller. The resilient element is mounted between the pushing unit and the casing. The needle hub is inserted into the container and controlled by the driver assembly push the needle out. After the needle is used, the location of the pressing unit, the controller and the pushing unit keeps the needle from protruding from the casing. When a new needle hub replaces the used needle hub, the pressing unit, the controller and the pushing unit will return to their original locations. People will not forget to change the used needle because the device cannot be operated with a used needle. Furthermore, the safety lancet device will decrease the danger of infection.
Further benefits and advantages of the present invention will become apparent after a careful reading of the detailed description with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a safety lancet device in accordance with the present invention;
FIG. 2 is a partially exploded perspective view of the safety lancet device in FIG. 1 ;
FIG. 3 is a perspective view of a driver assembly of the safety lancet device in FIG. 1 ;
FIG. 4 is an exploded perspective view of the driver assembly in FIG. 3 ;
FIG. 5A is a cross sectional front view of the safety lancet device in FIG. 1 before being used;
FIG. 5B is a cross sectional side view of the safety lancet device in FIG. 5A ;
FIG. 6A is an operational cross sectional front view of the safety lancet device in FIG. 1 with a top cap of the safety lancet device pressed;
FIG. 6B is an operational cross sectional side view of the safety lancet device in FIG. 6A ;
FIG. 7A is an operational cross sectional front view of the safety lancet device in FIG. 1 with a pushing unit pushing a needle hub of the safety lancet;
FIG. 7B is an operational cross sectional side view of the safety lancet device in FIG. 7A ;
FIG. 8A is an operational cross sectional front view of the safety lancet device in FIG. 1 with a pressing unit to separate the needle hub of the safety lancet pressed;
FIG. 8B is an operational cross sectional side view of the safety lancet device in FIG. 8A ;
FIG. 9A is an operational cross sectional front view of the safety lancet device in FIG. 1 with a now needle hub being inserted into a container of the safety lancet device;
FIG. 9B is an operational cross sectional side view of the safety lancet device in FIG. 9A ;
FIG. 10 is an exploded perspective view of another embodiment of a needle hub in accordance with the present invention; and
FIG. 11 is a side view in partial section of the needle hub in FIG. 10 ; and
FIG. 12 is a front view in partial section of the needle hub in FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 1 and 2 , a safety lancet device in accordance with the present invention comprises a casing ( 10 ), a driver assembly ( 20 ) and a needle hub ( 30 ).
The casing ( 10 ) preferably comprises a front casing ( 12 ), a rear casing ( 14 ), a bottom ring ( 16 ), a top ring ( 18 ) and a top cap ( 19 ).
The front casing ( 12 ) comprises a proximal end (not numbered), a distal end (not numbered), an inner surface (not numbered), an outer surface (not numbered), multiple annular ribs ( 120 ), a guide slot ( 122 ) and multiple recesses ( 124 ). The multiple annular ribs ( 120 ) are formed around and extend radially inward from the inner surface near the proximal end. Preferably, the front casing ( 12 ) has two annular ribs ( 120 ). The guide slot ( 122 ) is formed longitudinally through the front casing ( 12 ) near the distal end. The recesses ( 124 ) are formed radially around and inward from the outer surface respectively of the distal end and the proximal end. Preferably, the proximal end and the distal end have respectively a recess ( 124 ).
With further reference to FIGS. 5A and 5B , the rear casing ( 14 ) engages the front casing ( 12 ) to form a cylindrical casing and comprises a proximal end (not numbered), a distal end (not numbered), an inner surface (not numbered), an outer surface (not numbered), multiple annular ribs ( 140 ) and multiple recesses ( 144 ). The multiple annular ribs ( 140 ) are formed around and extend radially inward from the inner surface near the proximal end and correspond to the annular ribs ( 120 ) on the front casing ( 12 ). Preferably, the rear casing ( 20 ) has two annular ribs ( 140 ). The recesses ( 144 ) are formed around and extend radially inward from the outer surface respectively at the distal end and the proximal end and correspond to the recesses ( 124 ) on the front casing ( 12 ). Preferably, the proximal end and the distal end have a recess ( 144 ).
The bottom ring ( 16 ) optionally is cylindrical, comprises a proximal end (not numbered), a distal end (not numbered), an inside surface (not numbered) and an annular ring ( 160 ) and engages the proximal ends of the front casing ( 12 ) and the rear casing ( 14 ). The annular ring ( 160 ) is formed on the inside surface, extends radially inward from the proximal end of the bottom ring ( 16 ) and engages the recesses ( 124 , 144 ) in the proximal ends of the front casing ( 12 ) and the rear casing ( 14 ).
The top ring ( 18 ) engages the distal ends of the front casing ( 12 ) and the rear casing ( 14 ). The top cap ( 19 ) comprises a proximal end ( 190 ) and a distal end (not numbered). The proximal end ( 190 ) passes through the top ring ( 16 ) and is attached to the driver assembly ( 20 ). Preferably, the proximal end ( 190 ) has an outer surface (not numbered) and an outer thread (not shown) formed on the outer surface.
With further reference to FIGS. 3 to 5 , the driver assembly ( 20 ) is mounted in the casing ( 10 ) and comprises a container ( 40 ), a pressing unit ( 50 ), a controller ( 60 ), a pushing unit ( 70 ) and a resilient element ( 80 ).
The container ( 40 ) is cylindrical, is mounted securely in the casing ( 10 ) and comprises a proximal open end (not numbered), a distal open end (not numbered), an inner surface (not numbered), an outer surface (not numbered), an outer diameter (not numbered), an inner diameter (not numbered), a middle (not numbered), an optional slot ( 41 ), multiple optional annular flanges ( 42 ), multiple optional longitudinal recesses ( 43 ), multiple optional gaps ( 44 ), multiple optional grooves ( 46 ), an annular protrusion ( 48 ) and multiple side slots ( 49 ). The optional slot ( 41 ) is formed through the proximal open end and has a cross shape. The multiple annular flanges ( 42 ) are formed around and extend radially outward from the outer surface near the middle. Preferably, the container ( 40 ) has two annular flanges ( 42 ). The multiple optional longitudinal recesses ( 43 ) are formed longitudinally in the inner surface at the proximal open end. The optional gaps ( 44 ) are formed respectively in the annular flange ( 42 ). The multiple optional grooves ( 46 ) are formed longitudinally in the inner surface of the distal open end. Preferably, the container ( 40 ) has two grooves ( 46 ). The annular protrusion ( 48 ) is formed integrally with and extends inward from the inner surface in the middle and has an inner surface (not numbered), an inner diameter (not numbered) and a top (not numbered). The side slots ( 49 ) are formed through the outer surface, between the annular protrusion ( 48 ) and the distal open end and comprise a top (not numbered) and a bottom (not numbered). Preferably, the container ( 40 ) has two side slots ( 49 ).
The pressing unit ( 50 ) is cylindrical, is mounted slidably around the distal open end of the container ( 40 ) and comprises a proximal end (not numbered), a distal end (not numbered), an inner diameter (not numbered), multiple protruding keys ( 52 ), an optional thumb tab ( 54 ), a rod ( 56 ) and an optional tab ( 58 ). The inner diameter of the pressing unit ( 50 ) corresponds to the outer diameter of the container ( 40 ). Each protruding key ( 52 ) has a bottom (not numbered) and is formed integrally with and extends outward from the distal end. Preferably, the pressing unit ( 50 ) has two protruding keys ( 52 ). The optional thumb tab ( 54 ) is formed on and extends outward from the distal end. The rod ( 56 ) is formed on and extends downward from the proximal end and has a free end (not numbered). The optional tab ( 58 ) is formed on and extends inward from the free end of the rod ( 56 ).
With further reference to FIG. 6A , the controller ( 60 ) is cylindrical, is mounted slidably in the distal open end of the container ( 40 ) and comprises a proximal end (not numbered), a distal end (not numbered), an outer diameter (not numbered), an outer surface (not numbered), an inner surface (not numbered), an optional top annular ring ( 62 ), multiple optional longitudinal ribs ( 63 ), multiple arced controller tabs ( 64 ), an inner annular ring ( 66 ) and an optional inner threaded (not shown). The outer diameter of the controller ( 60 ) corresponds to the inner diameter of the container ( 40 ). The optional annular ring ( 62 ) is formed on and extends radially outward from the outer surface of the proximal end. Each arced controller tab ( 64 ) has an attached end (not numbered) and a free end (not numbered). The attached end of the arced controller tab ( 64 ) is formed on and extends from the outer surface. The multiple arc controller tabs ( 64 ) correspond respectively to the protruding key ( 52 ) of the pressing unit ( 50 ), the grooves ( 46 ) and the side slot ( 49 ) of the container ( 40 ). Preferably, the controller ( 60 ) has two arced controller tabs ( 64 ). The multiple optional longitudinal ribs ( 63 ) are formed longitudinally on the outer surface and connect to the annular ring ( 62 ). Preferably, the arced controller tabs ( 64 ) extend respectively from the longitudinal ribs ( 63 ). The inner annular ring ( 66 ) is formed on and extends radially inward from the inner surface near the distal end and has an inner diameter smaller than the inner diameter of the annular protrusion ( 48 ) of the container ( 40 ). The optional inner thread is formed on the inner surface of the proximal end.
The pushing unit ( 70 ) is slidably mounted in the controller ( 60 ) and comprises a proximal closed end (not numbered), a distal closed end (not numbered), an outer diameter (not numbered), a head ( 71 ), multiple arced tabs ( 72 ) and an optional neck ( 73 ). The top cap ( 19 ) of the casing ( 10 ) is mounted securely on the pushing unit ( 70 ). The outer diameter of the pushing unit ( 70 ) is smaller than the inner diameter of the inner annular ring ( 66 ) in the controller ( 60 ). The head ( 71 ) is formed on and extends upward from the distal closed end and has an outer diameter. The outer diameter of the head ( 71 ) is larger than the inner diameter of the inner annular ring ( 66 ) in the controller ( 60 ). Each arced tab ( 72 ) is formed on and extends downward from the head ( 71 ) and has an attached end (not numbered), a free end (not numbered) and an outer diameter (not numbered). The free ends press against the pushing unit ( 70 ). The outer diameter of the arced tabs ( 72 ) is smaller than the inner diameter of the annular protrusion ( 48 ) in the container ( 40 ). Preferably, the pushing unit ( 70 ) has two arced tabs ( 72 ). The optional neck ( 73 ) is formed near the distal closed end, and the arced tabs ( 72 ) correspond to the neck ( 73 ).
The resilient element ( 80 ) is mounted between the pushing unit ( 70 ) and the top cap ( 19 ) of the casing ( 10 ).
The needle hub ( 30 ) is slidably mounted in the proximal open end of the container ( 40 ).
A first embodiment of the needle hub ( 30 ) in accordance with the present invention comprises a needle sleeve ( 31 ) and a needle core ( 32 ).
The needle sleeve ( 31 ) comprises a proximal open end (not numbered), a distal closed end (not numbered), an inner surface (not numbered), an outer surface (not numbered), multiple optional longitudinal grooves ( 33 ), multiple optional longitudinal ribs ( 35 ), a hole ( 37 ) and multiple positive limits ( 39 ). The multiple optional longitudinal grooves ( 33 ) are formed in the inner surface. The multiple optional longitudinal ribs ( 35 ) are formed on the outer surface and correspond to the optional longitudinal recesses ( 43 ) in the container ( 40 ). The hole ( 37 ) is formed in the distal closed end. The multiple positive limits ( 39 ) are formed respectively on the longitudinal notches ( 33 ) near the proximal open end.
The needle core ( 32 ) is mounted slidably in the needle sleeve ( 31 ), protrudes from the hole ( 37 ) and optionally comprises a proximal end (not numbered), a distal end (not numbered), a middle (not numbered), a top plate ( 34 ), multiple protrusions ( 36 ), multiple resilient core members ( 38 ), a detachment joint ( 320 ) and a needle ( 322 ). The top plate ( 34 ) is formed on the proximal end and has an outer surface (not numbered). The multiple protrusions ( 36 ) are formed on the outer surface of the top plate ( 34 ) and correspond to the longitudinal recesses ( 33 ) to limit the needle core ( 32 ) in the needle sleeve ( 31 ). The resilient core members ( 38 ) are attached to the top plate ( 34 ) and the distal closed end of the needle sleeve ( 31 ) and are mounted between the needle core ( 32 ) and the needle sleeve ( 31 ). The detachment joint ( 320 ) is formed in the middle of the needle core ( 32 ), and the needle ( 322 ) is attached to the needle core ( 32 ) and extends through the detachment joint ( 320 ).
With further reference to FIGS. 10 to 12 , a second embodiment of the needle hub ( 30 ′) comprises a needle sleeve ( 31 ′) and a needle core ( 32 ′).
The needle sleeve ( 31 ′) comprises a proximal open end (not numbered), a distal closed end (not numbered), an inner surface (not numbered), an outer surface (not numbered), multiple optional flat tapers ( 310 ′), multiple optional longitudinal grooves ( 33 ′), multiple optional longitudinal ribs ( 35 ′), a hole ( 37 ′) and multiple positive limits ( 39 ′). The multiple optional longitudinal grooves ( 33 ′) are formed in the inner surface. The multiple optional longitudinal ribs ( 35 ′) are formed on the outer surface and correspond to the longitudinal grooves ( 43 ) in the container ( 40 ). The hole ( 37 ′) is formed in the distal closed end. The multiple positive limits ( 39 ′) are formed respectively in the longitudinal grooves ( 33 ′) near the proximal open end. The multiple flat tapers ( 310 ′) are formed in the inner surface of the distal closed end.
The needle core ( 32 ′) is mounted slidably in the needle sleeve ( 31 ′), protrudes from the hole ( 37 ′) and comprises a proximal end (not numbered), a distal end (not numbered), a middle (not numbered), a top plate ( 34 ′), multiple protrusions ( 36 ′), multiple middle arced tabs ( 38 ′), multiple longitudinal keys ( 321 ′), a needle ( 324 ′), a detachment joint ( 326 ′) and a needle point sheath ( 328 ′). The top plate ( 34 ′) is formed on the proximal end and has an outer surface (not numbered). The multiple protrusions ( 36 ′) are formed on the outer surface of the top plate ( 34 ′), correspond to the longitudinal recesses ( 33 ′) to hold the needle core ( 32 ′) in the needle sleeve ( 31 ′) and comprise respectively at least one nub ( 360 ′). The nub ( 360 ′) is formed on and extends outward from the protrusions ( 36 ′) to abut the longitudinal groove ( 33 ′) in the needle sleeve ( 31 ′). The multiple longitudinal keys ( 321 ′) are formed on and extend outward from the middle of the needle core ( 32 ′), correspond respectively to the longitudinal grooves ( 33 ′) to guide the movement of the needle core ( 32 ′) and comprise multiple nubs ( 323 ′). The multiple nubs ( 323 ′) are formed on and extend outward from the longitudinal keys ( 321 ′) to abut the longitudinal grooves ( 33 ′) in the needle sleeve ( 31 ′). Preferably, the needle core ( 32 ′) has two longitudinal keys ( 321 ′). The multiple middle arced tabs ( 38 ′) are formed on the middle and between the longitudinal keys ( 321 ′) of the needle core ( 32 ′) and comprise respectively attached ends (not numbered) and free ends (not numbered). The free ends of the middle arced tabs ( 38 ′) abuts the flat tapers ( 310 ′) in the needle sleeve ( 31 ′). The detachment joint ( 326 ′) is formed in the middle of the needle core ( 32 ′) and separates to form the needle point sheath ( 328 ′). The needle ( 324 ′) is mounted in the middle of the needle core ( 32 ′) and is located at the detachment joint ( 326 ′). After separating the needle point sheath ( 328 ′) from the needle core ( 32 ′), the needle ( 324 ′) will protrude from the hole ( 37 ′) in the needle sleeve ( 31 ′) when the driver assembly ( 20 ) pushes the top plate ( 34 ′) of the needle core ( 32 ′). The middle arced tabs ( 38 ′) will move along the flat tapers ( 310 ′), and the needle ( 324 ′) will protrude from the hole ( 37 ′) in the needle sleeve ( 31 ′). When the pushing force is removed, the tension in the middle arced tabs ( 38 ′) will return the needle core ( 32 ′) to the original location, and the needle ( 324 ′) will draw back into the needle sleeve ( 31 ′).
The first embodiment of the needle hub ( 30 ) is used as the example in the following description.
With further reference to FIGS. 5A and 5B , the driver assembly ( 20 ) and the needle hub ( 30 ) are mounted in the casing ( 10 ) before the safety lancet device is used. The needle hub ( 30 ) is inserted into the proximal open end of the container ( 40 ), and the longitudinal rib ( 35 ) on the needle sleeve ( 31 ) engages the longitudinal recesses ( 43 ) in the container ( 40 ). The container ( 40 ) is mounted securely in the front casing ( 12 ) and the rear casing ( 14 ), and the annular flanges ( 42 ) of the container ( 40 ) intervene between the annular ribs ( 120 , 140 ) of the front casing ( 12 ) and the rear casing ( 14 ). The thumb tab ( 54 ) protrudes from the guide slot ( 122 ) in the front casing ( 12 ). The pressing unit ( 50 ) is slidably mounted around the distal open end of the container ( 40 ), the rod ( 56 ) is located in the gap ( 44 ) in the container ( 40 ), and the tab ( 58 ) is located in the slot ( 41 ) in the container ( 40 ). The controller ( 60 ) is slidably mounted in the distal open end of the container ( 40 ) with the longitudinal ribs ( 63 ) are mounted respectively in the grooves ( 46 ) and the arced controller tabs ( 64 ) slidably mounted in the side slot ( 49 ) in the container ( 40 ). The pushing unit ( 70 ) is slidably mounted in the controller ( 60 ) and the container ( 40 ). The inner annular ring ( 66 ) of the controller ( 60 ) stops the head ( 71 ) of the pushing unit ( 70 ), and the arced tabs ( 72 ) protrude from the inner annular ring ( 66 ) of the controller ( 60 ). The free end of the arced tabs ( 72 ) are attached to the top of the annular protrusion ( 48 ) in the container ( 40 ). The resilient element ( 80 ) is mounted on the pushing unit ( 70 ).
With further reference to FIGS. 6A and 6B , turning and separating the detachment joint ( 320 ) of the needle core ( 32 ) exposes the needle ( 322 ). After pushing the top cap ( 19 ), the controller ( 60 ) is pushed. The longitudinal ribs ( 63 ) move in the grooves ( 46 ), and the arced controller tabs ( 63 ) move in the side slot ( 49 ). Since the arced tabs ( 72 ) in the pushing unit ( 70 ) still abut the top of the annular protrusion ( 48 ), the resilient element ( 80 ) is compressed between the top cap ( 19 ) and the pushing unit ( 70 ).
With further reference to FIGS. 7A and 7B , the arced controller tabs ( 64 ) move to the bottom of the side slot ( 49 ), and the inner annular ring ( 66 ) presses the arced tabs ( 72 ) against the neck ( 73 ) as the resilient element ( 80 ) is compressed. When the arced tabs ( 72 ) are pressed completely against the neck ( 73 ), the arced tabs ( 72 ) are released by the annular protrusion ( 48 ) and move down inside the inner surface of the annular protrusion ( 48 ). The resilient element ( 80 ) drives the pushing unit ( 70 ) against the needle core ( 32 ). The resilient core members ( 38 ) are compressed, and the needle ( 322 ) protrudes from the hole ( 37 ) in the needle sleeve ( 31 ) momentarily. The resilient core members ( 38 ) press against the top plate ( 34 ) and retract the needle ( 322 ) back into the needle sleeve ( 31 ). The needle ( 322 ) will not protrude for any appreciable time so the needle ( 322 ) will not prick anyone other than the intended person. With the arced tabs ( 72 ) of the pushing unit ( 70 ) inside the inner surface of the annular protrusion ( 48 ), pushing the top cap ( 19 ) again will not have enough force to overcome the resilient core members ( 38 ), and the needle ( 322 ) will not protrude from the needle sleeve ( 31 ).
With further reference to FIGS. 8A and 8B , the used needle hub ( 30 ) is ejected by pushing the thumb tab ( 54 ) on the pressing unit ( 50 ) in the guide slot ( 122 ) in the front casing ( 12 ). The rod ( 56 ) with the tab ( 58 ) moves in the slot ( 41 ) in the container ( 40 ), and the tab ( 58 ) pushes the needle hub ( 30 ) out of the container ( 40 ). When the pressing unit ( 50 ) is pressed down completely, the protruding keys ( 52 ) move below the arced controller tabs ( 64 ) that abut the bottom of the protruding keys ( 52 ).
With further reference to FIGS. 9A and 9B , inserting a new needle hub ( 30 ) into the proximal open end of the container ( 40 ) pushes the rod ( 56 ) with the tab ( 58 ), the pressing unit ( 50 ), the protruding keys ( 52 ) of the pressing unit ( 50 ), the arc controller tabs ( 64 ), the controller ( 60 ), the inner annular ring ( 66 ) of the controller ( 60 ) and the head ( 71 ) of the pushing unit ( 70 ) until the arced controller tabs ( 64 ) stop in the top of the side slot ( 49 ) and the arced tabs ( 72 ) of the pushing unit ( 70 ) are released from the inner surface of the annular protrusion ( 48 ) and abut the top of the annular protrusion ( 48 ) in the container ( 40 ). Continuing to push, the protruding keys ( 52 ) of the pressing unit ( 50 ) release from the arced controller tabs ( 64 ) and return to the original location before use. The safety lancet device is ready for use again.
According to the safety lancet device in accordance with the present invention, the used needle hub must be changed before the safety lancet device can be used again.
Although the invention has been explained in relation to its preferred embodiment, many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed. | A safety lancet device has a casing, a driver assembly and a needle hub with a needle. The driver assembly and the needle hub are mounted within the casing. The driver assembly comprises a container, a pressing unit, a controller, a pushing unit and a resilient unit. The needle hub is controlled by the driver assembly to make the needle momentarily protrude. After the needle is used, the location of the driver assembly keeps the needle from protruding. When a new needle hub replaces the used needle hub, the driver assembly will return to the original location before use and can drive the needle momentarily from the casing. Users will not forget to change the used needle. Furthermore, the safety lancet device will decrease the danger of infection. | 0 |
This application is a continuation of application Ser. No. 09/243,845 now U.S. Pat. No. 6,110,105, filed Feb. 3, 1999 which prior application is incorporated by reference.
BACKGROUND OF THE INVENTION
Arthroscopes and other like optical instruments, such as endoscopes, have long been known in the field of surgery and in other fields. In this specification and in the appended claims the term “arthroscope” means and should be interpreted to include an endoscope or any other like optical instrument, whether used for surgery or otherwise. In this application, the invention is described in connection with an instrument employed for surgery, as in human surgery.
Over the last fifteen or more years the nature of surgery has changed substantially, with minimally invasive surgery becoming a mainstay. Within the orthopedic community, in particular, arthroscopy and similar techniques have become the most common surgical procedures. Surgery using such techniques is less painful for the patient and, in most instances, can be performed more quickly and safely than with techniques that require greater invasion of the patient's body; anesthesia is also less complicated, the surgery can often be handled on an outpatient basis, and the procedures are better from the standpoint of cost effectiveness. Patients return to normal life more quickly, and hospital stays may be reduced in length or even eliminated. However, all of these benefits are available only if the minimally invasive surgery allows for better diagnostic capabilities, improved surgical techniques, and reduced iatrogenic damage. Similar benefits are available with other, non-surgical, instruments.
One problem in these minimally invasive techniques derives from limitations in the arthroscopes, endoscopes and other principal optical instruments employed. In particular, the rather limited field of view afforded by even the best instruments commercially available in 1998 has inhibited progress to at least some extent; available instruments and techniques have not changed dramatically since 1985. A substantial improvement in the field of view available to a person employing an arthroscope or like instrument for exploratory or repair procedures is much needed.
Several techniques for modification (widening) of the view offered by arthroscopic/endoscopic instruments have been proposed, but they have not been especially successful. Generally, such proposals have required packing a plurality of movable lenses or prisms into the input end of the instrument; the resulting problems of precision of construction, precision of relative movements, space requirements, optical distortions, and elimination of undesired “ambient” light have been substantial. This is not particularly surprising; interaction between the prisms and lenses involved, along with light loss, exacerbates the problem.
SUMMARY OF THE INVENTION
It is an object of this invention, therefore, to provide a new and improved arthroscope that affords the user a broadened effective field of view with few or no added lenses or prisms, a minimum of movable parts, and no requirement for movement of the instrument to vary its scope of view.
A related object of the invention is to afford a new and improved arthroscope that is relatively simple and effective in construction, cost efficient and durable, yet has an improved and expanded field of view.
Accordingly, the invention relates to a variable view arthroscope comprising an elongated housing having an image input end spaced from an outer control end. An input lens, preferably a diverging type lens, closes (and usually seals) the image input end of the housing tube, which is beveled at an angle of 30° to 60°. Lighting means are provided for illuminating a working image area beyond the image input end of the housing tube. An input lens, located in the input end of the housing tube, intercepts light reflected back from the working area. That reflected light constitutes a working image. The light image reflected from the working area back through the input lens is directed to a movable mirror. The movable mirror may be rotatable or it may move linearly. There is a control member, usually an elongated control rod, for varying the position of the movable mirror to any position or to a series of fixed positions between a first limit position and a second limit position. A fixed mirror is positioned to intercept light from the movable mirror, re-directing that light toward a relay lens located near the fixed mirror position. A relay lens assembly directs the light image from the fixed mirror through the length of the relay lens assembly to impinge upon a focusing lens assembly. The focusing lens assembly consists of focusing and zoom lens and their controls and is preferably located in the control portion of the arthroscope.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a variable view arthroscope constructed in accordance with a preferred embodiment of the invention;
FIG. 2 is an elevation view of the instrument of FIG. 1;
FIG. 3 is a plan view, on an enlarged scale, of the control portion of the arthroscope of FIGS. 1 and 2;
FIG. 4 is an elevation view, on an enlarged scale, of the control portion of the instrument of FIGS. 1 and 2;
FIG. 5 is a detail view taken approximately as indicated by line 5 — 5 in FIG. 3;
FIG. 6A is a sectional, longitudinal elevation view, on an enlarged scale, of the image input end of the arthroscope of FIG. 1, adjusted for a maximum upward view;
FIG. 6B is a sectional elevation view, like FIG. 6A, of the image input end of the arthroscope of FIG. 1, adjusted for an intermediate view;
FIG. 6C is a sectional elevation view, like FIGS. 6A and 6B, of the image input end of the arthroscope of FIG. 1, adjusted for a maximum downward view;
FIG. 6D is a sectional view taken approximately along line 6 D— 6 D in FIG. 6A;
FIG. 7A is an elevation view, on an enlarged scale, of a slide member used in the arthroscope of FIG. 1;
FIG. 7B is a plan view of the slide of FIG. 7A;
FIG. 7C is an end view of the slide of FIGS. 7A and 7B;
FIG. 8A is a plan view, on an enlarged scale, of a cam/axle member used in the control end (FIG. 3) of the arthroscope of FIG. 1;
FIG. 8B is an end view of the cam/axle member of FIG. 8A;
FIG. 8C is an elevation view of the cam/axle member of FIG. 8A;
FIG. 9A is a plan view, on an enlarged scale, of two control knobs from the control end (FIG. 3) of the arthroscope of FIG. 1;
FIG. 9B is an end view of the control knobs of FIG. 9A;
FIG. 9C is a section view, taken approximately along line 9 C— 9 C in FIG. 9A, of the control knobs;
FIG. 10 is an elevation view, on an enlarged scale, of the lighting apparatus for the arthroscope of FIG. 1;
FIG. 11A is a longitudinal sectional elevation view, like FIG. 6A, of the input (viewing) end of an arthroscope comprising another embodiment of the invention, adjusted for a maximum upward view;
FIG. 11B is a sectional elevation view, like FIG. 11A, of the apparatus of FIG. 11A adjusted for an intermediate view;
FIG. 11C is a sectional elevation view, like FIG. 11A, adjusted for a maximum downward view;
FIG. 12A is a plan view of the slide and cam/axle member used in the control end (FIG. 3) of the arthroscope of FIG. 1 shown in a center position;
FIG. 12B is a cross-sectional view taken along line 12 B-D of FIG. 12 A and shown in a center position;
FIG. 12C is a cross-sectional view taken along line 12 B-D of FIG. 12 A and showing the slide in a moved position to the right of its position of FIG. 12A; and
FIG. 12D is a cross-sectional view taken along line 12 B-D of FIG. 12 A and showing the slide in a moved position of FIG. 12 A.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One preferred embodiment of the invention is illustrated as an arthroscope 30 , shown in FIGS. 1-10.
As shown in FIGS. 1 and 2, arthroscope 30 includes an elongated housing tube 31 , which has an image input end 32 and a control end 33 . Housing tube 31 , and more specifically its control end 33 , may extend into the outer control portion 35 of arthroscope 30 , shown in greater detail in FIGS. 3-5. As shown in FIGS. 1-4, the control portion 35 , from which the control end 33 of the housing tube 31 of arthroscope 30 projects, ends with a CCD attachment 36 . The CCD attachment 36 is connected by appropriate means to an image screen (not shown) to be viewed by a person using arthroscope 30 . Because CCD attachment 36 may be of conventional construction and does not constitute a part of the present invention, it has not been shown in detail.
As best shown in FIG. 2 and in the enlarged views of FIGS. 6A-6C, the image input end 32 of housing tube 31 is of beveled construction at its extreme end; the bevel is usually between 30° and 60°. The outer end of housing tube 31 , shown in enlargement in FIGS. 6A-6C, is closed by a diverging input lens 37 (plural lenses may be used). Input lens 37 is shown as having an outer concave surface 38 spaced from an inner concave surface 39 . Input lens 37 is preferably sealed into the tip of the input end 32 of housing tube 31 ; a suitable seal material to mount lens 37 in place in the end of housing tube 31 is any conventional sealing adhesive approved by the FDA for in vivo use. Input lens (or lenses) 37 may be formed of optical glass or any other suitable lens material. When a single input lens is used, input lens 37 preferably has a rim matched as closely as possible to the inside diameter of the housing tube 31 at its image input end 32 to assure a good seal between the housing tube and the input lens. Similar expedients should be employed if plural input lenses are utilized.
Arthroscope 30 includes, an outer control portion 35 and a light source 41 that is connected to a lighting means or apparatus 42 ; see FIGS. 2 and 4. The lighting assembly 42 includes one or more optic fiber bundles 43 ; the fiber optic bundle (or bundles) extend to the input end of the arthroscope; see FIGS. 4 and 6D. The optic fiber bundles 43 have been omitted in FIGS. 6A-6C (and in other Figures) because they may be conventional in construction. The lighting assembly 42 is utilized to illuminate a surgical working area (not indicated) beyond the image input end 32 of the housing tube; illumination of the surgical working area may be made through the input lens 37 .
A control member, shown in FIG. 4 as a control rod 45 , extends longitudinally through the housing tube 31 from outer control portion 35 to its input end 32 . Rod 45 is used to vary the position of a slidably movable mirror (See arrows A in FIGS. 6A-6C) having a base 46 and a mirror surface 47 along the axis of rod 45 . Mirror surface 47 is shown as planar in the drawings, but the movable mirror may be concave or other shapes. The mirror surface 47 is aligned with but spaced from the inner surface 39 of input lens 37 . See FIGS. 6A-6C. The end of control rod 45 is affixed to the movable mirror base 46 , as best shown in the enlarged views of FIGS. 6A-6C. A suitable commercially available adhesive may be used to join the end of rod 45 to the base 46 of the movable mirror; alternatively, soldering or brazing may be used if desired. The tip of control rod 45 may be polished and coated to afford a suitable movable mirror, eliminating the need for a separate part 46 .
At the control end 35 of the arthroscope 30 the control rod 45 extends into and engages a slide 48 . Slide 48 is driven linearly by means of two control knobs 49 and 50 , as described hereinafter in connection with FIGS. 9A-9C.
In the arthroscope 30 , as best shown in FIGS. 6A-6C, the base 46 of the movable mirror 46 , 47 slides linearly between a maximum upward view position (FIG. 6 A), through an intermediate position (FIG. 6 B), to a maximum downward view position (FIG. 6 C). Of course, the movement of the movable mirror base 46 may be reversed, moving from its maximum downward position (FIG. 6C) toward its maximum upward position (FIG. 6 A). The images that may be provided to a surgeon by the arthroscope 30 all overlap. The maximum upward view of FIG. 6A, with movable mirror 46 , 47 advanced by control rod 45 to a position immediately adjacent input lens 37 , has an overlap of about fifty percent with the maximum downward view (FIG. 6C) afforded when the sliding mirror 46 , 47 is fully retracted.
At the top of the input end of arthroscope 30 , as seen in FIGS. 6A-6C, there is a fixed mirror comprising a. base 51 and a reflective (mirror) surface 52 . The fixed mirror surface 52 intercepts a light image from the movable mirror surface 47 and re-directs that light image to impinge upon the input end 53 A of a relay lens assembly 53 . Relay lens assembly 53 , FIGS. 6A-6C, may be of conventional construction having an outer stainless sleeve 54 for stability and directs the light toward a receptor, shown as a focusing lens assembly 55 (FIGS. 1, 2 , 3 and 4 ). The focusing lens assembly 55 consists of focusing and zoom lens and is of conventional design. The focusing lens assembly 55 directs the light image in the customary manner, into the CCD attachment 36 ; see FIGS. 14. A slide 48 is located in the control portion 35 of arthroscope 30 ; the slide, shown in FIGS. 7A-7C, comprises a main body 57 having an axial relay lens opening 58 , the relay lens opening 58 also extends through an enlarged end 59 of the slide. A socket 61 also in slide 48 , formed to align and attach control rod 45 to slide 48 , is best shown in FIG. 7 B. The control rod socket 61 , in the illustrated embodiment, is located directly below the axial opening 58 for the relay lens.
The cam portion 65 of cam/axle member 62 is positioned in a central transverse opening 63 in slide 48 ; see FIGS. 7A-7C for opening 63 , FIGS. 8A-8C for cam/axle member 62 .
Opening 63 is not quite circular in cross-section; it is enlarged or “stretched” slightly, as is most apparent in FIG. 7 B. The cam/axle member 62 includes a large control knob shaft attachment segment 64 of circular cross-section, cam segment 65 contains a relay lens assembly slot 66 , and a small control knob shaft attachment segment 67 . This preferred construction is shown in detail in FIGS. 8A-8C. Two control knobs, shown in FIGS. 9A-9C, are mounted on the outer ends 64 and 67 of cam/axle member 62 (FIGS. 8 A- 8 C). The. control knobs include a right-hand control knob 49 that is fitted onto the large control wheel shaft attachment segment 64 of the cam/axle member 62 . The second or left-hand control knob 50 fits onto the smaller control knob shaft attachment segment 67 of cam/axle member 62 . See FIGS. 8A-8C, 9 A- 9 C and 12 A- 12 D.
The control knobs 49 and 50 and their shaft attachments 64 and 67 , respectively, may be connected to each other by conventional means. Either of the control knobs 49 and 50 can be used to rotate cam 65 within slide opening 63 , thus causing slide 48 and the attached control rod 45 , to move linearly in relation to the rotational motion of cam/axle 62 through a distance 68 as shown in FIGS. 12C and 12D. FIG. 12C shows the slide 48 moved to a rearward position closest to the control end 33 of the housing tube 31 . FIG. 12D shows the slide 48 moved to a forward position closest to the image input end 32 of the housing tube 31 .
The lighting assembly 42 , illustrated in FIG. 2 and shown in greater detail in FIG. 10, may include a condenser lens 71 to focus light from a suitable source 41 onto one end 72 of the light bundles 43 that extend to the input end of the arthroscope 30 . See FIG. 6 D. Actually, there may be two or more fiber optic light bundles 43 ; to supply light to the input end of arthroscope 30 . As previously noted, the lighting assembly may be quite conventional in construction and hence has been described only generally.
Operation of the arthroscope 30 , (FIGS. 1 - 10 ), can now be considered. At the outset, light from source 41 (FIG. 2) is focused upon the end 72 of one or more fiber optic bundles 43 , as by an appropriate lens 71 (FIG. 10 ). As a consequence, a surgical working area just beyond the input end 32 of the arthroscope 30 (FIGS. 1 and 2) is illuminated. In arthroscope 30 , illumination is effected through input lens 37 (FIGS. 6 A- 6 C). Light from bundle(s) 43 , at least in part, reflects from the fixed mirror 51 , 52 onto the reflective surface 47 of the movable mirror, and through the input lens 37 into the area to be illuminated.
A light image reflected from the surgical working area, after passing through input lens 37 , impinges on the inclined reflective surface 47 of the movable mirror 46 , 47 . That light image is directed from the movable mirror surface 47 to impinge upon the reflective surface 52 of the fixed mirror 51 . From the fixed mirror the light image is re-directed toward the input end 53 A of the relay lens assembly 53 ; see FIGS. 6A-6D. The relay lens system 53 supplies the image to the CCD attachment. 36 , through focusing lens assembly 55 , to be viewed by the surgeon or other person using the arthroscope 30 .
If the person using arthroscope 30 is dissatisfied with the image available through the CCD attachment 36 , control knobs 49 and/or 50 may be used to vary the image. That is, the control knobs, through cam/axle member 62 (FIGS. 8 A- 8 C), slide 48 (FIGS. 7 A- 7 C), and rod 45 (FIGS. 6A-6C) can be used to advance the movable mirror 46 , 47 toward the input lens 37 (see FIG. 6 A), or to retract the movable mirror from the input lens (see arrow A in FIGS. 6B and 6C) to a “lower” position. In this way the image supplied to the surgeon or other person using the instrument 30 can be and is varied to a substantial extent with no change in the position of the instrument. In effect, the overall viewing range of the instrument 30 is enhanced by at least thirty degrees with no need to reposition the instrument axially. Further correction of the image can be afforded by appropriate software.
FIGS. 11A, 11 B and 11 C afford sectional elevation views of the input end 132 of a modified instrument; thus, FIGS. 11A, 11 B and 11 C correspond to FIGS. 6A, 6 B and 6 C, respectively. In FIGS. 11A-11C, the reference numerals and illustrated elements correspond to those employed in FIGS. 6A-6C, except for those elements that have been modified. Thus, the instrument input end 132 of a housing tube 131 is beveled, as previously described, and is closed by an input lens 37 . The input lens 37 may have two concave lens surfaces, an outer surface 38 and an inner surface 39 as shown; other input lens structures may be used. A fixed mirror base 51 is mounted in the upper portion of housing tube 31 , immediately adjacent input lens 37 ; the fixed mirror base 51 has a reflective coating on its surface 52 that faces the input end 53 A of a relay lens assembly 53 .
In the modification shown in FIG. 11A, there is a pivotally movable mirror comprising a base 146 having a reflective surface 147 . The mirror base 146 is pivotally mounted on a shaft 148 that extends transversely of the instrument between the two sides 170 (only one shown) of a generally U-shaped support member 171 positioned in the lower part of housing tube 131 . The movable mirror base 146 is connected to the end of a control rod 145 , as by a pin 172 ; rod 145 is similar to rod 45 . The control rod 145 can be moved linearly as indicated by arrow B in FIGS. 11A, B and C.
The views of FIG. 11 B and FIG. 11C are the same as FIG. 11A except that FIG. 11 B shows the pivotally movable mirror 146 , 147 at an intermediate position, for an intermediate image, and FIG. 11C shows the pivotally movable mirror 146 , 147 positioned for a maximum “downward” view. It should be understood that FIGS. 11A-11C are assumed to be vertically oriented. They could equally well be horizontally oriented, as could FIGS. 6A-6C, so that references to “upward” and “downward” could equally well be modified to “right” and “left”, or vice versa. Because the control rod 145 acts as previously described for rod 45 , and because only the movable mirror has been changed, from linear movement to rotational movement, it is believed to be unnecessary to provide any further description, structural or operational, of the arrangement shown in FIGS. 11A-11C.
Several parts of instrument 30 can be changed from those illustrated without appreciable effect on overall operation of instrument 30 . For example, input lens 37 , the shape of the movable mirrors 46 , 47 and 146 , 147 and the illustrated relay lens assembly 53 can be changed, as can the lighting assembly 42 , 43 . It will be recognized that the control rod 45 (or rod 145 ) may be modified; it constitutes a preferred mechanism for operating the movable mirror but any desired alternative that will move that mirror, whether linearly or along a pivotal or other required path, can be used. The angle of the level of the outer end of housing tube 31 may be varied as desired; a level of 30° to 60° is preferred, but may depend on the primary use for instrument 30 . It will be recognized that use of a CCD unit for a display is not essential. The “software” used for the display may vary appreciably. Any preferred technique to enable the instrument user to move the movable mirror over its operational range is acceptable. | A variable-view arthroscope or like instrument (endoscope, etc.) includes an elongated housing tube extending from an outer control end to an inner image input end that is closed by an input lens; the input lens preferably is a diverging lens. In the form shown in FIGS. 6 A- 6 C, the input lens has a concave inner surface and a concave outer surface. A lighting apparatus illuminates a surgical working area beyond the image end of the housing tube; the illumination may be projected outwardly through the input lens. A movable mirror intercepts light reflected from the surgical working area to produce a working image that is reflected to a fixed mirror that in turn reflects the working image to impinge upon the input end of a relay lens assembly. The working image is transmitted to a receptor, which is located near the outer (control) end of the housing tube. The relay lens applies the image to an image device, such as a conventional CCD unit, that transmits the image to a location exterior to the scope. A control member, shown as a control rod extending longitudinally within the housing tube, varies the position of the movable mirror between first and second limits, adding about 30° or more to the image available to a user of the instrument. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to vulcanizable molding materials, and more particularly, those that are peroxide vulcanizable by means of the action of heat. In another aspect, the present invention relates to a method of manufacture of such materials.
In particular, polymers which have no or only few double bonds available in the molecule must be cross-linked with peroxide. The most important peroxide cross-linkable polymer types in this connection are: ethylene vinyl acetate EVA), ethylene propylene copolymerizates (EPM), ethylene propylenediene copolymerizate (EPDM), silicon rubber and polyethylene.
It is possible, with peroxidic cross-linking, to produce C-C bridges between two polymer chains which bridges are responsible for good ageing and compression set of the rubber article on account of their high bonding energy and the short bonding length. Peroxidic cross-linking is therefore also used when extreme requirements (e.g. the use of rubber articles in hot, aggressive media) are placed on the article.
The permanent deformation (compression set) of a mixture (measured according to ASTM D 395) is of great importance as a factor for the stability and accuracy of size and, accordingly, for the use especially of industrial articles, e.g. seals, rollers, hoses, and the like, but also for use on shoe soles. The lower the compression set, the higher the utility of the rubber product (e.g. tightness of a seal).
One possibility for improving this property as well as others is the use of bifunctional organosilicon compounds.
DE-A8 23 28 630 teaches a method for the peroxidic cross-linking of polyethylene in which polyethylene is reacted with an organosilicon compound containing an olefinically unsaturated group in the presence of a compound supplying free radicals. This product is then treated with a silanol condensation catalyst and water.
In practice, vinyl silanes are used practically exclusively for this purpose; however, they have a number of disadvantages: they exhibit a low flash point and, in addition, a high volatility on account of their low boiling point, which proves to be a problem at the temperatures used in the rubber industry, especially when being mixed in, when the silane is not yet bound to the filler used as reinforcing filler. Further disadvantages of the use of vinyl silanes are short ultimate elongations, extremely poor tearing resistances, low energies at break and a poor fatigue behavior in the particular vulcanizates.
SUMMARY OF THE INVENTION
An object of the invention is to provide peroxidically cross-linkable (vulcanizable) molding materials in which the disadvantages are largely avoided but at the same time a compression set is obtained similar to that found when using vinyl silanes.
In attaining the above and other objects, one feature of the invention is to provide molding materials vulcanizable by means of the action of heat with peroxides, comprising at least one polymer, customary auxiliary agents, silicate filler and an organosilicon compound. The molding compositions of the present invention are characterized in that they contain as organosilicon compound 0.1 to 50 parts by weight, preferably 1-15 parts by weight, relative to 100 parts by weigh a thiocyanatopropyltrialkoxysilane of the formula (I)
(RO).sub.3 Si--(CH.sub.2).sub.3 --SCN
in which R corresponds to an alkyl group with 1 to 8 carbon atoms.
The basic compositions of peroxidically vulcanizable synthetic polymeric molding materials in general are known to persons skilled in the art. Any suitable polymers of this type can be used for purposes of the present invention.
The polymers are especially ethylene vinyl acetate (EVA), ethylene propylenediene copolymerizate (EPDM). silicon rubber and polyethylene or their mixtures, to the extent that they can be mixed with each other.
Examples of cross-linking agents are:
1,1-bis-(tert.-butylperoxy)-3,3,5-trimethylcyclohexane,
tert.-butylperoxyisopropylcarbonate,
tert.-butylperoxybenzoate,
dicumylperoxide,
α,α-bis-(tert.-butylperoxy)-diisopropylbenzene,
2,5-dimethyl-2,5-di-(tert.-butylperoxy)-hexane,
2,5-dimethyl-2,5-di-(tert.-butylperoxy)-hexyne-3,
di-tert.-butylperoxide, and the like, which are added in an amount of approximately 1 to 10 parts by weight per 100 parts by weight of the polymer.
DETAILED DESCRIPTION OF THE INVENTION
As a rule, the molding materials contain generally known natural or synthetic silicate fillers (e.g. clays, kaolins, precipitated and pyrogenic silicas, silicates, etc) with BET surfaces (measured with nitrogen) between 1 and 1000 m 2 /g, preferably 5 to 300 m 2 /g, with whose hydroxyl groups the trialkoxysilyl groups of the compounds used in accordance with the invention react, splitting off an alcohol and thus resulting in a chemical bond between the filler and silane.
Generally, 5 to 250 parts by weight, preferably 20 to 100 parts by weight relative to 100 parts by weight of the polymer are used.
The filler is either separately introduced into the molding composition or incorporated together with the organosilicon compound. A premixture or a filler reacted with the organosilicon compound can be used for this purpose.
Methods of manufacturing fillers modified in this manner are described in EP patent 0,177,674 and in German application P 40 04 781.4. If the compounds to be used in accordance with the invention are added to the mixture to be vulcanized in situ or also in modified form, this results in a lowering of the viscosity of the mixture and thus in a better workability.
The vulcanizable molding materials of the invention are manufactured according to the generally known methods. The components are mixed--except for the peroxidic cross-linking agent--in any desired sequence until a homogenous mixture has been achieved.
After the addition of the peroxide and the suitable elevation of temperature, the vulcanization begins. The traditional components, as they are generally used, include e.g. anti-ageing agents, softeners, auxiliary processing agents, stabilizers, pigments as well as other organosilicon compounds with a different structure. Any one or more of these components can be added in a suitable amount sufficient to perform their expected function. It turned out that as regards the compression set values, the molding materials of the invention are comparable to molding materials containing vinyl silanes. Improvements result from the significantly longer ultimate elongation, the higher energy at break, the improved tearing resistances and the better fatigue behavior of the vulcanized molding materials of the invention.
The following examples emphasize the advantages of the molding materials of the invention over the state of the art.
______________________________________Test standards for the evaluation: Test method Units______________________________________Tensile strength DIN 53 504 MPaUltimate elongation DIN 53 504 min.Energy at break DIN 53 504 JTearing resistance DIN 53 507 N/mmMooney viscosity DIN 53 523/524 ME (Mooney unit)Compression set B ASTM D 395 %De Mattia ASTM D 813 Kc______________________________________
The following names and abbreviations, the meaning of which is listed here, are used in the examples of application:
______________________________________Buna AP 451 EPDM of the Bayer companyKeltan 778 EPDM of the DSM companyPerkadox 14/40 1,3-bis-(tert.-butyl-peroxyl-isopropyl)- benzeneA 172 triethoxyvinyl silane of UCCSi 264 3-thiocyanatopropyltriethoxysilaneDurosil precipitated silica from Degussa (BET = 60 m.sup.2 /g)TRIM activatorFlexon 876 paraffinic softenerProtector G 3108 antiozone waxWeissoel 530 paraffinic softenerSuprex Clay aluminum silicateVulkanox HS 2,2,4-trimethyl-1,2-dihydroquinolineWinnofil S precipitated calcium carbonate______________________________________
EXAMPLE 1
Si 264 in a Peroxidically Cross-linked Cable Jacket Mixture Based on EPDM Compared with a Mixture without Silane
______________________________________ 1 2______________________________________Keltan 778 100 100Weissoel 10 10Winnofil S 50 50Suprex Clay 100 100Flexon 876 25 25ZnO RS 5 5Protector G 3108 5 5Vulkanox HS 1 1TRIM 1.5 1.5Si 264 -- 2Perkadox 14/40 5 5Mooney viscosity ME 64 57ML 4 (100° C.)Vulcanizate data: 180° C./t.sub.95%Molulus 300% MPa 4.2 7.8Compression set22 h/70° C. % 20.8 16.370 h/100° C. % 20.0 14.1______________________________________
Si 264 results in an improvement of the processing behavior, an elevation of the modulus and in an improvement of the compression set values.
EXAMPLE 2
Si 264 in a Peroxidically Cross-linked EPDM Mixture (Computer Pads) Compared with Vinyl Silane
______________________________________ 1 2______________________________________Buna AP 451 100 100Durosil 60 60A 172 1 --Si 264 -- 1Perkadox 14/40 4 4Vulcanizate data: 180° C./t.sub.95%Tensile strength MPa 12.1 13.3Ultimate elongation % 120 210Energy at break J 20.6 41.7Tearing resistance N/mm 8 15Compression set 70 h/100° C. % 7.2 6.8Fatigue behavior - De MattiaCrack formation without punctureKilocycle until 0.100 0.7crack length 25 mm______________________________________
Si 264 exhibits, in comparison to vinyl silane, a clearly longer ultimate elongation, a better fatigue behavior, a higher energy at break and a better tearing resistance at almost the same compression set value.
Further variations and modifications of the foregoing will be apparent to those skilled in the art and are intended to be encompassed by the claims appended hereto.
German priority application No. P 40 00 217.2 is relied on and is incorporated herein by reference. | Moulding materials vulcanizable by means of the action of heat which contain a thiocyanatopropyltrialkoxysilane and a method of their manufacture are disclosed. | 2 |
This application is a continuation of application Ser. No. 08/081,572, filed Jun. 23, 1993, now abandoned.
FIELD OF INVENTION
This invention relates to oligonucleotide (ODN) based therapeutics, particularly the treatment of infections of the human immunodeficiency virus (HIV).
BACKGROUND OF THE INVENTION
The present invention relates to ODNs suitable for use in treatment of HIV infected individuals by inhibition of replication of HIV in infected cells.
HIV is responsible for the disease that has come to be known as acquired immunodeficiency syndrome (AIDS). Although initially recognized in 1981, no cure has yet been found for this inevitably fatal disease. HIV is spread by a variety of means such as sexual contact, infected blood or blood products and perinatally. Because of the complexity of HIV infection and the paucity of effective therapies, a great deal of effort has been expended in developing methods for detecting, treating and preventing infection. Diagnostic procedures have been developed for identifying infected persons, blood and other biological products.
The HIV genome has been well characterized. Its approximately 10 kb encode sequences containing regulatory segments for HIV replication as well as the gag, pol and env genes coding for the core proteins, the reverse transcriptase-protease-endonuclease, and the internal and external envelope glycoproteins, respectively. HIV tends to mutate at a high rate causing great genetic variation between strains of the viruses and indeed between virus particles of a single infected individual. There are a few "conserved" regions of the HIV genome which tend not to mutate. These regions are presumed to encode portions of proteins essential for virus function which can thus withstand very few mutational events.
The HIV env gene encodes the glycoprotein, gp160, which is normally processed by proteolytic cleavage to form gp120, the external viral glycoprotein, and gp41, the viral transmembrane glycoprotein. The gp120 remains associated with HIV virions by virtue of noncovalent interactions with gp41. These noncovalent interactions are weak, consequently most of the gp120 is released from cells and virions in a soluble form.
Like most viruses, HIV often elicits the production of neutralizing antibodies. Unlike many other viruses and other infectious agents for which infection leads to protective immunity, however, HIV specific antibodies are insufficient to halt the progression of the disease. Therefore, in the case of HIV, a vaccine that elicits the immunity of natural infection could prove to be ineffective. In fact, vaccines prepared from the HIV protein gp160 appear to provide little immunity to HIV infection although they elicit neutralizing antibodies. The failure to produce an effective anti-HIV vaccine has led to the prediction that an effective vaccine will not be available until the end of the 1990's. Therapeutic agents currently used in treatment of AIDS often cause severe side-effects which preclude their use in many patients. It would, thus, be useful to have alternative methods of treating and preventing the disease that do not entail vaccination and currently available pharmaceutical agents.
Recently, attempts have been made to moderate protein production associated with viral infections by interfering with the mRNA molecules that direct their synthesis. By interfering with the production of proteins, it has been hoped to effect therapeutic results with maximum effect and minimal side effects. It is the general object of such a therapeutic approach to interfere with or otherwise modulate gene expression leading to undesired protein formation.
One method for inhibiting specific gene expression which is believed to have promise is the "antisense" approach. Single-stranded nucleic acid, primarily RNA, is the target molecule for ODNs that are used to inhibit gene expression by an antisense mechanism. A number of workers have reported such attempts: Stein and Cohen (1988) Cancer Res., 48:2659-2668; Walder (1988) Genes & Development, 2:502-504; Marcus-Sekura (1988) Anal. Biochem., 172:289-295; Zon (1987) J. Pro. Chem., 6:131-145; Zon (1988) Pharm. Res., 5:539-549; Van der Krol et al. (1988) Biotechniques, 6:958-973; and Loose-Mitchell (1988) TIPS, 9:45-47. Antisense ODNs are postulated to exert an effect on target gene expression by hybridizing with a complementary RNA sequence. The hybrid RNA-ODN duplex appears to interfere with one or more aspects of RNA metabolism including processing, translation and metabolic turnover. Chemically modified ODNs have been used to enhance nuclease stability and cell permeability.
Duplex DNA can be specifically recognized by oligomers based on a recognizable nucleomonomer sequence. The motif termed "GT" recognition has been described by Beal et al. (1992) Science, 251:1360-1363; Cooney et al. (1988) Science, 241:456-459; and Hogan et al., EP Publication 375408. In the G-T motif, the ODN is oriented antiparallel to the target purine-rich sequence and A-T pairs are recognized by adenine or thymine residues and G-C pairs by guanine residues.
Sequence-specific targeting of both single-stranded and duplex target sequences has applications in diagnosis, analysis, and therapy. Under some circumstances wherein such binding is to be effected, it is advantageous to stabilize the resulting duplex or triplex over long time periods.
Covalent crosslinking of the oligomer to the target provides one approach to prolong stabilization. Sequence-specific recognition of single-stranded DNA accompanied by covalent crosslinking has been reported by several groups. For example, Vlassov et al. (1986) Nuc. Acids Res., 14:4065-4076, describe covalent bonding of a single-stranded DNA fragment with alkylating derivatives of nucleomonomers complementary to target sequences. A report of similar work by the same group is that by Knorre et al. (1985) Biochimie, 67:785-789. It has also been shown that sequence-specific cleavage of single-stranded DNA can be mediated by incorporation of a modified nucleomonomer which is capable of activating cleavage. Iverson and Dervan (1987) J. Am. Chem. Soc., 109:1241-1243. Covalent crosslinking to a target nucleomonomer has also been effected using an alkylating agent complementary to the single-stranded target nucleomonomer sequence. Meyer et al. (1989) J. Am. Chem. Soc., 111:8517-8519. Photoactivated crosslinking to single-stranded ODNs mediated by psoralen has been disclosed. Lee et al. (1988) Biochem., 27:3197-3203. Use of crosslinking in triple-helix forming probes has also been disclosed. Horne et al. (1990) J. Am. Chem. Soc., 112:2435-2437.
Use of N 4 ,N 4 -ethanocytosine as an alkylating agent to crosslink to single-stranded and double-stranded oligomers has also been described. Webb and Matteucci (1986) J. Am. Chem. Soc., 108:2764-2765; (1986) Nuc. Acids Res., 14:7661-7674; and Shaw et al. (1991) J. Am. Chem. Soc., 113:7765-7766. These papers also describe the synthesis of ODNs containing derivatized cytosine. The synthesis of oligomers containing N 6 ,N 6 -ethanoadenine and the crosslinking properties of this residue in the context of an ODN binding to a single-stranded DNA has been described. Matteucci and Webb (1987) Tetrahedron Letters, 28:2469-2472.
In a recent paper, sequence-specific binding of an octathymidylate conjugated to a photoactivatable crosslinking agent to both single-stranded and double-stranded DNA is described. Praseuth et al. (1988) Proc. Natl. Acad. Sci. (USA), 85:1349-1353. In addition, targeting duplex DNA with an alkylating agent linked through a 5'-phosphate of an ODN has been described. Vlassov et al. (1988) Gene 313-322; and Fedorova et al. (1988) FEBS Lett., 228:273-276.
In effecting binding to obtain a triplex, to provide for instances wherein purine residues are concentrated on one chain of the target and then on the opposite chain, oligomers of inverted polarity can be provided. By "inverted polarity" is meant that the oligomer contains tandem sequences which have opposite polarity, i.e., one having polarity 5'→3' followed by another with polarity 3'→5' or vice versa. This implies that these sequences are joined by linkages which can be thought of as effectively a 3'--3' internucleoside junction (however the linkage is accomplished), or effectively a 5'--5' internucleoside junction. Such oligomers have been suggested as by-products of reactions to obtain cyclic ODNs. Capobionco et al. (1990) Nuc. Acids Res., 18:2661-2669. Compositions of "parallel-stranded DNA" designed to form hairpins secured with AT linkages using either a 3'--3' inversion or a 5'--5' inversion have been synthesized. van de Sande et al. (1988) Science, 241:551-557. In addition, triple helix formation using oligomers which contain 3'--3' linkages have been described. Horne and Dervan (1990) J. Am. Chem. Soc., 112:2435-2437; and Froehler et al. (1992) Biochem., 31:1603-1609.
The use of triple helix (or triplex) complexes as a means for inhibition of the expression of target gene expression has been previously adduced (International Application No. PCT/US89/05769). Triple helix structures have been shown to interfere with target gene expression (International Application No. PCT/US91/09321; and Young et al. (1991) Proc. Natl. Acad. Sci., 88:10023-10026), demonstrating the feasibility of this approach.
Various modifications have been found to be suitable for use in ODNs. Oligomers containing 5-propynyl modified pyrimidines have been described. Froehler et al. (1992) Tetrahedron Letters, 33:5307-5310. 2'-Deoxy-7-deazaadenosine and 2'-deoxy-7-deazaguanosine have been incorporated into ODNs and assessed for binding to the complementary DNA sequences. Thermal denaturation analysis (Tm) has shown that these substitutions modestly decrease the Tm of the duplex when these analogs are substituted for 2'-deoxyadenosine and 2'-deoxyguanosine. Seela and Kehne (1987) Biochem., 26:2232-2238; and Seela and Driller (1986) Nuc. Acids Res., 14:2319-2332. It has also been shown that ODNs which alternate 2'-deoxy-7-deaza-adenosine and -thymidine can have a slightly enhanced duplex Tm over ODNs containing 2'-deoxy-adenosine and -thymidine. Seela and Kehne (1985) Biochem., 24:7556-7561.
2',3'-dideoxydeazapurine nucleosides have been used as chain terminators for DNA sequencing. 7-propargyl amino linkers are used for incorporation of fluorescent dyes into the nucleoside triphosphates
DNA synthesis via amidite and hydrogen phosphonate chemistries has been described. U.S. Pat. Nos. 4,725,677; 4,415,732; 4,458,066; and 4,959,463.
Prior attempts at antisense inhibition of HIV have focused on inhibition of the synthesis of some particular viral protein thought to be essential to the success of the infection and to RNAs which are believed to have important biological function. It has now been found that inhibition of viral gene expression and replication can be more efficiently achieved by targeting the conserved sites of the viral RNAs that signal the synthesis of conserved HIV proteins, particularly the p24 core antigen protein.
SUMMARY OF THE INVENTION
The present invention is directed to ODNs comprising nucleotide sequences sufficiently complementary to conserved regions of human immunodeficiency virus genetic material such that when bound to said region, the ODNs effectively prevent expression of the genetic material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an autoradiograph of a SDS-PAGE showing in vivo synthesis of HIV proteins and their breakdown products. FIG. 1 is described in Example 3.
FIG. 2 is an autoradiograph of a SDS-PAGE showing significant inhibition of expression of the HIV proteins by an antisense ODN directed against the rev sequence. FIG. 2 is described in Example 4.
FIG. 3 is an autoradiograph of a SDS-PAGE showing significant inhibition of expression of HIV proteins by antisense ODN directed against the first splice donor site of the HIV-1 genome. FIG. 3 is discussed in Example 5.
FIG. 4 is an autoradiograph of a SDS-PAGE showing the effects of different concentrations of antisense ODNs on HIV-gene product synthesis. FIG. 4 is discussed in Example 6.
FIG. 5 is an autoradiograph of a SDS-PAGE showing the concentration dependent inhibitory effects of ODN GPI-2A on p24 expression in HIV infected cells.
FIG. 6 is a bar graph showing the concentration dependent inhibitory effects of ODN GPI-2A on p24 expression in HIV infected cells.
DETAILED DESCRIPTION OF THE INVENTION
Several conserved sites within HIV RNA have now been found to be effective targets for the inhibition of expression of viral gene products by antisense ODNs and their analogues. The inhibition is based on the capacity to block certain functions during viral replication as measured by production of p24. The clinical importance of p24, a cleavage product of p55, is evidenced by the fact that serum levels of antibody to p24 antigen of HIV provide evidence of the effectiveness of immune response to the virus as well as serving as a marker of free virus in the serum of patients with advanced stage AIDS. Goedert et al. (1989) N. Engl. J. Med., 321:114.
According to the present invention, 20mer/15mer sequences were designed and employed as anti-HIV chemotherapeutic agents. The mechanism of action of antisense chemotherapeutics may be solely due to binding to the mRNA or DNA so as to prevent translation or transcription, respectively. The mechanism of action may also be due to activation of RNase H and subsequent degradation of the RNA.
The sequences are conserved in at least two different HIV isolates, and, therefore the antisense ODNs are effective agents against a wide variety of HIV strains.
The sequences were synthesized based on the phosphoramidite chemistry of ODN synthesis on Applied Biosystems model 380D automated DNA synthesizer. They were purified using ODN purification cartridges and/or HPLC.
In therapeutic applications, the ODNs are utilized in a manner appropriate for treatment of a variety of conditions by inhibiting expression of the target genetic regions. For such therapy, the ODNs, alone or in combination can be formulated for a variety of modes of administration, including systemic, topical or localized administration. Techniques and formulations generally can be found in Remington's Pharmaceutical Sciences, Mack Publishing Co., Easton, Pa., latest edition. The ODN active ingredient is generally combined with a pharmaceutically acceptable carrier such as a diluent or excipient which can include fillers, extenders, binders, wetting agents, disintegrants, surface-active agents, or lubricants, depending on the nature of the mode of administration and dosage forms. Typical dosage forms include tablets, powders, liquid preparations including suspensions, emulsions and solutions, granules, capsules and suppositories, as well as liquid preparations for injections, including liposome preparations.
For systemic administration, injection is preferred, including intramuscular, intravenous, intraperitoneal, and subcutaneous. For injection, the ODNs of the invention are formulated in liquid solutions, preferably in physiologically compatible buffers such as Hank's solution or Ringer's solution. In addition, the ODNs can be formulated in solid form and redissolved or suspended immediately prior to use. Lyophilized forms are also included. Dosages that can be used for systemic administration preferably range from about 0.01 mg/Kg to 50 mg/Kg administered once or twice per day. However, different dosing schedules can be utilized depending on (i) the potency of an individual ODN at inhibiting the activity of its target DNA or RNA, (ii) the severity or extent of the pathological disease state, or (iii) the pharmacokinetic behavior of a given ODN.
Systemic administration can also be by transmucosal or transdermal means, or the compounds can be administered orally. For transmucosal or transdermal administration, penetrants appropriate to the barrier to be permeated are used in the formulation. Such penetrants are generally known in the art, and include, for example, bile salts and fusidic acid derivatives for transmucosal administration. In addition, enhancers can be used to facilitate permeation. Transmucosal administration can be through use of nasal sprays, for example, or suppositories. For oral administration, the ODNs are formulated into conventional oral administration forms such as capsules, tablets, and tonics.
For topical administration, the ODNs of the invention are formulated into ointments, salves, gels, or creams, as is generally known in the art. Formulation of the invention oligomers for ocular indications is based on standard compositions known in the art.
In addition to use in therapy, the ODNs of the invention can be used as diagnostic reagents to detect the presence or absence of the target nucleic acid sequences to which they specifically bind. The enhanced binding affinity of the invention ODNs is an advantage for their use as primers and probes. Diagnostic tests can be conducted by hybridization through either double or triple helix formation which is then detected by conventional means. For example, the ODNs can be labeled using radioactive, fluorescent, or chromogenic labels and the presence of label bound to solid support detected. Alternatively, the presence of a double or triple helix can be detected by antibodies which specifically recognize these forms.
The use of ODNs containing the invention substitute linkages as diagnostic agents by triple helix formation is advantageous since triple helices form under mild conditions and the assays can thus be carried out without subjecting test specimens to harsh conditions. Diagnostic assays based on detection of RNA often require isolation of RNA from samples or organisms grown in the laboratory, which is laborious and time consuming, as RNA is extremely sensitive to ubiquitous nucleases.
The ODN probes can also incorporate additional modifications such as modified sugars and/or substitute linkages that render the ODN especially nuclease stable, and would thus be useful for assays conducted in the presence of cell or tissue extracts which normally contain nuclease activity. ODNs containing terminal modifications often retain their capacity to bind to complementary sequences without loss of specificity. Uhlmann et al. (1990) Chem. Rev., 90:543-584. As set forth above, the invention probes can also contain linkers that permit specific binding to alternate DNA strands by incorporating a linker that permits such binding. Froehler et al. (1992) Biochem., 31:1603-1609; and Horne et al. (1990) J. Am. Chem. Soc., 112:2435-2437.
Incorporation of base analogs into probes that also contain covalent crosslinking agents has the potential to increase sensitivity and reduce background in diagnostic or detection assays. In addition, the use of crosslinking agents will permit novel assay modifications such as (1) the use of the crosslink to increase probe discrimination, (2) incorporation of a denaturing wash step to reduce background and (3) carrying out hybridization and crosslinking at or near the melting temperature of the hybrid to reduce secondary structure in the target and to increase probe specificity. Modifications of hybridization conditions have been previously described. Gamper et al. (1986) Nuc. Acids Res., 14:9943.
ODNs of the invention are suitable for use in diagnostic assays that employ methods wherein either the oligomer or nucleic acid to be detected are covalently attached to a solid support as described in U.S. Pat. No. 4,775,619. The ODNs are also suitable for use in diagnostic assays that rely on polymerase chain reaction (PCR) techniques to amplify target sequences according to methods described, for instance, in European Patent Publication No. 0 393 744. ODNs of the invention containing a 3' terminus that can serve as a primer are compatible with polymerases used in PCR methods such as the Taq or Vent™ (New England Biolabs) polymerase. ODNs of the invention can thus be utilized as primers in PCR protocols.
The ODNs are useful as primers that are discrete sequences or as primers with a random sequence. Random sequence primers can be generally about 6, 7, or 8 nucleomonomers in length. Such primers can be used in various nucleic acid amplification protocols (PCR, ligase chain reaction, etc.) or in cloning protocols. The substitute linkages of the invention generally do not interfere with the capacity of the ODN to function as a primer. ODNs of the invention having 2'-modifications at sites other than the 3' terminal residue, other modifications that render the ODN RNase H incompetent or otherwise nuclease stable can be advantageously used as probes or primers for RNA or DNA sequences in cellular extracts or other solutions that contain nucleases. Thus, the ODNs can be used in protocols for amplifying nucleic acid in a sample by mixing the ODN with a sample containing target nucleic acid, followed by hybridization of the ODN with the target nucleic acid and amplifying the target nucleic acid by PCR, LCR or other suitable methods.
The ODNs derivatized to chelating agents such as EDTA, DTPA or analogs of 1,2-diaminocyclohexane acetic acid can be utilized in various in vitro diagnostic assays as described in, for instance, U.S. Pat. Nos. 4,772,548, 4,707,440 and 4,707,352. Alternatively, ODNs of the invention can be derivatized with crosslinking agents such as 5-(3-iodoacetamidoprop-1-yl)-2'-deoxyuridine or 5-(3-(4-bromobutyramido)prop-1-yl)-2'-deoxyuridine and used in various assay methods or kits as described in, for instance, International Publication No. WO 90/14353.
In addition to the foregoing uses, the ability of the oligomers to inhibit gene expression can be verified in in vitro systems by measuring the levels of expression in subject cells or in recombinant systems, by any suitable method. Graessmann et al. (1991) Nuc. Acids Res., 19:53-59. In the present case, levels of p24 have been measured as indicative of virus replication.
All references cited herein are incorporated herein by reference in their entirety.
The first embodiment of the present invention is an ODN complementary to the region between the 5' long terminal repeat (LTR) and the first initiation codon (AUG) of the gag gene. This region contains highly conserved sequences required for efficient viral RNA packaging. Klotman and Wong-Staal (1991) in: The Human Retroviruses by Gallo & Jay, eds. Acad. Press. The antisense ODN is referred to as "anti-gag." The ODN is of sufficient length and complementarity to inhibit expression of the gag gene. The complementary site is from bases +262 to +281 as numbered according to Ratner et al. (1985) Nature, 313:277-283. In a preferred embodiment the anti-gag ODN has the specific sequence:
5' CCGCCCCTCGCCTCTTGCCG 3' (SEQ ID NO:1)
The second embodiment of the present invention is an ODN complementary to the sequence immediately downstream of the major splice acceptor site but upstream of the AUG initiation codon of the tat gene (3' of nucleotide 5358). Translation of this transcript is essential for efficient viral gene expression and replication. The antisense ODN is referred to as "anti-gag-pol." The ODN is of sufficient length and complementarity to inhibit expression of the gag-pol gene. The complementary site is from bases +5399 to +5418 as numbered according to Ratner et al. (1985). In a preferred embodiment the anti-gag-pol ODN has the sequence:
5' GGCTCCATTTCTTGCTCTCC 3' (SEQ ID NO:2)
The third embodiment of the present invention is an ODN complementary to the rev gene which is involved in the regulated expression of HIV structural genes. Feinberg et al. (1986) Cell, 46:807; and Sodroski et al. (1986) Nature, 321:412. It has previously been observed that cytoplasmic RNAs that encode the virion structural proteins gag, pol and env are not found in the absence of a functional rev gene product. Sodroski et al. (1986) Nature, 321:412-417; Knight et al. (1987) Science, 236:837-840; Malim et al. (1988) Nature, 335:181-183; and Hadzopoulou-Cladaras et al. (1989) J. Virol., 63:1265-1274. rev mutants of HIV-1 are incapable of inducing the synthesis of the viral structural proteins and are therefore replication defective. Sadaie et al. (1988) Science, 239:910. rev is, therefore, said to be important in governing the transition from the expression of the early regulatory genes to that of the late structural genes. Greene (1991) in Mechanisms of Disease. Ed. by F. Epstein. The antisense ODN is referred to as "anti-rev." The ODN is of sufficient length and complementarity to inhibit expression of the rev gene. The complementary site is from bases +5552 to +5566 as numbered according to Ratner et al. (1985). In a preferred embodiment the anti-rev ODN has the following sequence:
5' CCGCTTCTTCCTGCC 3' (SEQ ID NO:3)
The fourth embodiment of the present invention is an ODN complementary to the region within the second splice acceptor site. This region contains highly conserved sequences required for efficient viral RNA packaging. Klotman and Wong-Staal (1991) in: The Human Retroviruses by Gallo & Jay, eds. Acad. Press. The antisense ODN is referred to as "GPI-2A." The ODN is of sufficient length and complementarity to inhibit expression of the gag gene. The complementary site is from bases +1189 to +1208 as numbered according to Ratner et al. (1985). In a preferred embodiment, the GPI-2A ODN has the specific sequence:
5' GGTTCTTTTGGTCCTTGTCT3' (SEQ ID NO:1)
In a further preferred embodiment, the ODNs were chemically modified by substitution of the naturally occurring oxygen of the phosphodiester backbone with sulfur to form the corresponding phosphorothioate derivatives of the oligomers. The positions of the sulfur are as shown below.
Anti-gag: 5' C'CG'CC'CC'TC'GC'CTC'TTG'CC'G 3' (SEQ ID NO:4);
Anti-gagpol: 5' G'GC'TC'CA'TTTC'TTG'CTC'TC'C 3' (SEQ ID NO:5);
Anti-rev: 5' C'CG'C'TTCTTC'C'TGC'C 3' (SEQ ID NO:6); and
GPI-2A: 5' G'GTTC'TTTTG'GTCC'TTG'TC'T 3' (SEQ ID NO:7).
In accordance with the present invention, methods of modulating the expression of the p24 protein are provided. The targeted RNA, or cells containing it, are treated with the ODN analogs which bind to specific regions of the RNA coding for the HIV p24 core structural protein. The RNA targeted sites include regions involved in the mechanism of expression of the HIV p24 core structural protein.
The following examples are intended to illustrate, but not to limit, the invention. Efforts have been made to insure accuracy with respect to numbers used (e.g., amounts, temperatures, etc.), but some experimental errors and deviations should be taken into account. Unless indicated otherwise, parts are parts by weight, temperature is in degrees Centigrade, and pressure is at or near atmospheric.
EXAMPLE 1
Cell Culture
To determine the effect of antisense oligomer on viral gene expression, B4.14 cells, provided by Dr. David Rekosh, Microbiology Department, University of Virginia, were seeded at a cell density of 5,000-12,000 cells per well in 24-well/35 mm plastic tissue culture plates and were maintained in Iscove's Modified Dulbecco's Medium with 10% calf serum, 50 μg/ml gentamycin and 200 μg/ml hygromycin B at 37° C. in a humidified incubator with 5% CO 2 for a few hours. Subsequently, the incubated cells were washed and incubated under the same conditions with medium containing the indicated concentrations of ODN and 10% serum heat inactivated to reduce serum nuclease activity. The same oligomer sequences, but with switched polarity were used as controls.
EXAMPLE 2
Viral Antigen Assay
Cells cultured as described in Example 1 were labeled with 75 to 150 μCi/ml [ 35 S]-methionine (70% L-Methionine/15% L-Cysteine) in the presence of methionine-free medium containing 29.2 mg/100 ml glutamine, 50 μg/ml gentamycin, 200 μg/ml hygromycin B, 10% heat inactivated fetal calf serum plus the desired concentration of oligomer. The [ 35 S]-methionine concentration was 185 MBq and the specific activity was 1057 Ci/mmole). Labeled samples were subsequently washed with phosphate buffered saline (PBS) and resuspended in 200 μl lysis buffer comprised of 50 mM Tris, pH 7.2; 150 mM NaCl; 5 mM EDTA; 1% Triton-100; 0.2% Deoxycholic acid.
Culture medium containing labeled virus was treated with 10% Triton X-100 to a 1% final concentration to disrupt virus particles. The samples were preabsorbed with protein A-Sepharose beads for 30 min. at 4° C. [ 35 S]-methionine-labeled viral proteins were then immunoprecipitated for 2 hours using protein A-Sepharose beads and 2.5 μl/sample of polyclonal rabbit antiserum directed against HIV-1 p25/24, obtained from the National Institute of Allergy and Infectious Diseases (AIDS Research and Reference Reagent Program). The antibodies were obtained from National Institute of Allergy & Infectious Disease (AIDS Research & Reference Reagent Program) and MicroGeneSys, Inc.
The resulting pellets were washed 4 times with lysis buffer, once with lysis buffer containing 500 mM NaCl and finally once with TNE buffer comprised of 10 mM Tris, pH 7.2; 25 mM NaCl; 1 mM EDTA. Samples were then resuspended in 20-30 μl 2X SDS sample buffer, boiled for 5-10 min, applied to a 12.5% SDS polyacrylamide gel electrophoresis and then analyzed by electrophoresis, according to the method described by Laemmli (1970) Nature, 227:680-685. The results obtained are listed in Table 1 and in FIGS. 1-3. Percent inhibition is determined by densitometric analysis of the autoradiography. The first two ODNs (anti-gag and anti-tat) were phosphorothioate derivatives [sulfurization on alternate bases]. Inhibition was observed at ODN concentrations of 5 μM assayed after 3 days incubation with the oligomer. The third oligomer was a 15-mer phosphodiester derivative. Observed inhibition was at oligomer concentration of 200 μg/ml assayed after 6 days incubation with the oligomer.
TABLE 1______________________________________Preliminary ObservationInhibition of viral protein synthesisby antisense oligomer in B4.14 cells Com-Sequence 5'-3' plementary Func- % inhi-(SEQ ID NO: 1) Site tion bition______________________________________CCGCCCCTCGCCTCTTGCCG 262-281 Splice 30(SEQ ID NO: 2) DonorGGCTCCATTTCTTGCTCTCC 5399-5418 tat 30(SEQ ID NO: 3) initi- atorCCGCTTCTTCCTGCC 5552-5566 Rev 40______________________________________
EXAMPLE 3
FIG. 1 is an autoradiograph of a SDS-PAGE showing in vivo synthesis of HIV-1 viral proteins and their breakdown products. The following samples were run. Two hundred μl of CMT3 [wild-type (left)] and B4.14 [transfected line (right)] cell lysates following metabolic labeling with [ 35 S]-methionine were immunoprecipitated with rabbit serum against p24 viral antigen as described above. The positions of the viral proteins (p160; p55 and p24) are clearly visible in the B4.14 cell lysate but not in control cell line CMT3 cell lysate.
EXAMPLE 4
FIG. 2 is an autoradiograph of a SDS-PAGE showing a significant inhibition of expression of HIV proteins by the antisense ODN directed to the rev sequence. The following experiment was performed. Two hundred μl of B4.14 [transfected line] cell lysates following 3 days treatment with antisense [AS]; and sense, the inverse complement of the antisense oligomer [S]; and subsequent [ 35 S]-methionine labeling were immunoprecipitated with rabbit serum directed against p24 viral antigen as described above. Equal amounts of protein were loaded on each lane.
EXAMPLE 5
FIG. 3 is an autoradiograph of a SDS-PAGE showing a significant inhibition of expression of HIV proteins by the antisense ODN directed to the first splice site donor of the HIV-1 genome. The following experiment was performed. Two hundred μl of B4.14 [transfected cell line] cell lysates/medium following 6 days treatment with antisense [AS]; sense, the inverse complement of the antisense ODN [S]; and control [B4.14] cell lysate only]; and subsequent 35 S-methionine labeling were immunoprecipitated with rabbit serum directed against p24 viral antigen as described above. Equal amounts of protein were added in each lane.
EXAMPLE 6
The Effects of Different Concentrations of the Antisense ODNs
To determine whether there was a dose relationship of the antisense ODNs on HIV gene expression, the following experiment was performed.
The cells were cultured as described in Example 1 and incubated overnight with different concentrations of ODNs directed against the first splice donor site in the presence of 5 μg/ml Lipofectin and 1% heat-inactivated fetal calf serum. The medium was subsequently replaced with fresh medium containing 10% heat-inactivated serum. ODN was then added and incubated for 7 days. Western blot analysis was performed with rabbit polyclonal antibody directed against HIV p24/55 proteins.
Following SDS-polyacrylamide electrophoresis, cellular proteins were electrophoretically transferred to Immobilon membrane (Schleicher and Schuell) as follows. An Immobilon membrane was placed in methanol in a clean dish, washed several times in deionized distilled water and soaked in western transfer buffer (60.6 g Tris-HCl; 288 g glycine; 4 l methanol and distilled water to 20 l). The apparatus used is the Bio-Rad Trans-Blot cell, used according to the manufacturer's instructions. Western blot analysis was performed using the Vectastain ABC kit (Alkaline Phosphatase Rapid IgG) (Vector Laboratories) according to the manufacturer's instructions.
The results are shown in FIG. 4 where it can be seen that 0.5 and 1 μM antisense ODN are equally effective at preventing p24 synthesis.
EXAMPLE 27
The Effects of Different Concentrations of the ODN GPI-2A
To determine the ability of the ODN GPI-2A to inhibit expression of p24 in HIV infected cells, the following experiments were performed.
Cells were incubated overnight with 0.1, 0.5 and 1.0 μM of the ODN in the presence of 1% heat-inactivated fetal calf serum. The serum concentration was subsequently raised to 10% and incubated for 3 days. About 3×10 7 cpm/probe was immunoprecipitated using rabbit polyclonal antibody directed against p24/25 viral proteins as described above. The lane marked control had the sense strand, the inverse complement of the antisense oligomer, added to the cells rather than the sense strand. The autoradiograph in FIG. 5 shows that there was a dose-dependent inhibition of the HIV viral core antigen, among others.
The autoradiograph was then subjected to densitometry analysis. The results, presented in FIG. 6, indicate that at 1.0 μM, the ODN inhibited about 50% of the p24 synthesis.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 8(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:CCGCCCCTCGCCTCTTGCCG20(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:GGCTCCATTTCTTGCTCTCC20(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 15 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:CCGCTTCTTCCTGCC15(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 1(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 3(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 5(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 7(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 9(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 11(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 14(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 17(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 19(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:NCNCNCNTNGNCTNTTNCNG20(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 1(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 3(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 5(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 7(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 11(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 14(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 17(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 19(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:NGNTNCNTTTNTTNCTNTNC20(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 15 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 1(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 3(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 4(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 10(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 11(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 14(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:NCNNTTCTTNNTGNC15(2) INFORMATION FOR SEQ ID NO:7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 1(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 5(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 10(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 14(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 17(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(ix) FEATURE:(A) NAME/KEY: misc.sub.-- feature(B) LOCATION: 19(D) OTHER INFORMATION: /note= "This position is Cs whereins is sulfur."(xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:NGTTNTTTTNGTCNTTNTNT20(2) INFORMATION FOR SEQ ID NO:8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(xi) SEQUENCE DESCRIPTION: SEQ ID NO:8:GGTTCTTTTGGTCCTTGTCT20__________________________________________________________________________ | The present invention is directed to oligonucleotides comprising nucleotide sequences sufficiently complementary to conserved regions of human immunodeficiency virus genetic material such that when bound to said region, the oligonucleotides effectively prevent expression of the genetic material. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus for the heat treatment of at least one essentially cuboidal magazine for lead frames, which are parallel to a horizontal longitudinal direction of the magazine and are fitted with electronic chips, in at least one box which has a housing with a charging opening which is defined by end edges and can be closed by a door, and in which box at least one fan is arranged for subjecting the lead frames in the magazine to a hot gas.
2. Discussion of the Prior Art
Competitiveness in the mass production of semiconductors is nowadays in particular a question of the yield of qualitatively satisfactory components. The corresponding production batches must be made ready without a significant increase in costs and without an extended delivery time. This challenge calls for the use of processes and installations of very high reliability and productivity, it also being required that the smallest batch sizes can be processed without profitability being adversely affected by the batch size. For this purpose, various line concepts have been developed in order to feed lead frames arranged in magazines and fitted with electronic chips to individual wiring stations (so-called wire bonders). The lead frames are in this case passed from work station to work station.
One of these work stations comprises a curing installation, in which a so-called curing takes place, i.e. a hardening by polymerization of the epoxy resins, and here, in particular, of the adhesives which are used for fastening the electronic chips onto the lead frames.
For this purpose, until now a plurality of magazines with lead frames have been brought into a corresponding oven and subjected to hot gas (air or inert gas). This random heat treatment has considerable disadvantages, however, with respect to the curing process, the temperature profile, the stressing of the electronic components and the accompanying contamination of the components, of the lead frames and of the environment.
The object of the present invention is to provide a curing installation in which the abovementioned disadvantages do not occur, by the corresponding lead frames being treated in a specific and controlled manner such that uniform curing over the entire length of the lead frame takes place, and the electronic chips present on it are subjected to as little stressing as possible, keeping their contamination and the polluting of the environment to a minimum.
This object is achieved by the fan being supported on the housing and arranged therein in such a way that it generates in the region of the magazine at least one essentially horizontally directed gas stream which is essentially parallel to the longitudinal direction of the magazine, in order that the gas flows through the magazine.
As a result, the heat transfer between the gas and the electronic chips on the lead frames in the magazine is subsfantially increased, and consequently, the period of time which is required for heating up or cooling the electronic chips on the lead frames in the magazine is subsfantially reduced. Thus, the very temperature-sensitive electronic component parts of the electronic chips are subjected as little as possible and at the same time uniformly, to high temperatures. It is optimal to subject the chips to high temperatures only for as long as is necessary, in order, for example, to cure resins contained therein or, in general, to allow the desired chemical reactions to proceed therein.
Although the expectations with respect to the temperature consfancy in the magazine are already met in this exemplary embodiment, the time up until the electronic components on the gas outlet side of the magazine have virtually the same temperature as on the gas inlet side can be shortened still further.
SUMMARY OF THE INVENTION
Preferably, at least part of the heater is located on an essentially horizontal section of a gas stream leading from the magazine to the fan or from the fan to the magazine. In one design of the apparatus according to the invention, in this case the heater is of two parts, with one part of the heater in each case located on the respective sections of the gas streams leading from the magazine to the fan and from the fan to the magazine. By this arrangement of the heating, the risk of thermal stratifications is avoided, since the heated gas is swirled in the fan, and, consequently, is mixed very well.
Between the fan and the magazine there is preferably arranged at least one gas-conducting element, this gas conducting element preferably being designed as a baffle, wall, gas-conducting branch or the like. These gas-conducting elements bring about a specific conducfance of the gas stream to the lead frames in the magazine. The gas stream is sucked in by the heater and/or expelled by means of a corresponding fan, and then fed to the magazine with the lead frames, in order to flow through this magazine so that the lead frames are heat-treated.
In one design of the apparatus according to the invention, the fan is designed as a helical fan, i.e. as a fan with helical blades, with its shaft and its gas expulsion respectively extending and occurring in a direction which is essentially parallel to the longitudinal direction of the magazine, and the gas-conducting element is designed as a baffle which is seated between the magazine and the fan and together with the side walls of the housing of the box forms forced-flow ducts. In this case, the direction of the gas stream preferably is made variable by reversing the direction of rotation of the helical fan, for example by alternately reversing the direction of rotation of the blades. This reversal of the direction of rotation may be performed, for example, with a periodicity of 10 to 30 seconds, preferably of 10 seconds. Thus, the magazine can be subjected to hot gas from both sides, in order further to reduce non-uniformities of the heat transfer which would be caused, for example, by the low heat capacity of the gas flowing only slowly through the magazine, by which the heating capacity is to be brought into the interior of the magazine.
In another design of the apparatus according to the invention, at least one duct is formed by chamber walls acting as gas-conducting elements adjoining the fan, which duct conducts a gas stream on one side to the lead frames arranged in the magazine. In this case, the fan may be designed as a radial fan, i.e. as a fan with radial blades, while the direction of the gas stream is variable by opening or closing corresponding forced-flow ducts preferably by means of mechanically actuable shut-off plates or gates. By analogy with the preceding text and with equivalent reasons and advantages, this actuation of the shut-off plates or gates may be performed, for example, with a periodicity of 10 to 30 seconds, preferably of 10 seconds.
In yet another design of the apparatus according to the invention, two forced-flow ducts or guide ducts are formed by at least one baffle acting as a gas-conducting element, or by at least one wall acting as a gas-conducting element, by which ducts a gas stream is in each case guided from the magazine to a fan or from a fan to the magazine. In these two designs, the gas may be sucked in through the one duct from the magazine, heated and, if appropriate, fed through the other, for example opposite, duct to the magazine again, or vice versa.
In a further design of the apparatus according to the invention, in the box there are arranged two fans, which are designed as radial fans and subject the magazine to gas in respectively opposed directions. Consequently, in this design, the gas can be sucked in an upper or lower region of the box in respectively opposed directions through the one duct from the magazine, heated, and fed through the other, for example opposite, duct to the magazine again. Preferably, in this case, each fan is assigned a gas-conducting branch, preferably provided with an annular flange, this gas-conducting branch being seated in a wall which adjoins a rear wall of the box and forms a guide duct towards the magazine. In this case, the heater may be designed as a heating spiral and be arranged between the gas-conducting branches of the two fans, a helix axis of the heating spiral being arranged essentially vertically and respective longitudinal axes of the gas-conducting branches being arranged essentially horizontally. In this case, a distribution of the gas stream in the box may be varied periodically by simulfaneous reversal of the direction of rotation of the two fans, for example by the direction of rotation of the blades being alternately reversed. By analogy with the preceding text and with equivalent reasons and advantages, this joint reversal of the direction of rotation of the two fans may be performed, for example, with a periodicity of 10 to 30 seconds, preferably of 10 seconds.
These preferred measures or their various combinations according to the invention have the effect of achieving, inter alia, an improved and therefore accelerated heating of the gas in the box and/or of the lead frames in tile magazine. In particular, the use of two fans and the joint periodic reversal of their direction of rotation leads to a compensation, respectively in the upper and lower subregions of the box, for rather higher speeds of the gas flow in the one direction of throughflow, by rather lower speeds of the gas flow in the other direction of throughflow, converse conditions respectively applying for the upper subregion and lower subregion of the box. As a result, the heat treatment, for example curing, proceeds much more uniformly, and is also speeded up.
For driving, the fans are preferably provided with respective motors, for example electric motors, and are connected thereto by means of shafts, the motors respectively being arranged outside the housing of the box, rotating in tile same sense and being arranged on approximately opposite side wall strips of the housing. In this case, tile essentially vertical side wall strips preferably run obliquely away from an essentially vertical rear wall of the housing of the box, this rear wall being narrower than the essentially vertical charging opening of the box. Preferably, in addition to this, with the corresponding design of the apparatus with two fans, in each case a gas-conducting branch and a shaft may have essentially congruent longitudinal axes which meet essentially at the center point of tile heating spiral, or on the helix axis, of the latter, and preferably form an obtuse angle, so that the fans are arranged so as to be obliquely inclined with respect to each other.
These preferred measures achieve the effect, inter alia, that the fans centrifuge the gas into a closed chamber and, on tile other hand, this gas circulates only through a well-defined and optimally designed guide duct. As a result, a predetermined and aligned gas stream is ensured.
The oblique inclination of the fans brings still further major advantages. Firstly, it is known that any deflection of the gas leads to a pressure drop, so that a desired gas stream is greatly reduced. For this reason, in the box according to the invention there should be as few deflections of the gas as possible. This is achieved by the oblique inclination, since the knee formed there tends to lead rather more to an improved introduction of the gas by virtue of the wall radiation towards the magazine. A further advantage is that the side wall part in which the motor is seated may be obliquely designed. Accordingly, the rear wall of the box is designed to be shorter in comparison with the door or charging opening. As a result, there forms next to the box a free space into which only the motor protrudes, the motor not protruding however beyond the principal plane of the side wall. Consequently, it is possible to place a plurality of boxes one next to the other and also one above the other without them hindering one another. Furthermore, such an arrangement needs only a very small interior space, which in turn has a positive effect on the gas flow.
Preferably, in the box there is provided a magazine carrier which is thermally isolated from the housing and on which at least one magazine can be supported in a position centered approximately in front of the charging opening. In this way, the magazine can be arranged at medium height in the box and, as a result, be subjected more evenly to the gas stream.
In this case, a temperature sensor may be arranged essentially at the center of the magazine carrier and thermally coupled to it, the magazine carrier shielding the temperature sensor from direct heat irradiation by the heating spiral of the heater. Furthermore, in the box there may be provided, in addition to the temperature sensor, at least two gas-temperature sensors which are arranged in relation to each other at essentially the same height, and of which in, each case, at least one is assigned to the gas stream of, respectively, one of the two forced-flow ducts, or guide ducts in order to sense its temperature. In this way, the temperature of the components in the magazine can be ascertained best and can be monitored optimally.
For driving the fan, preferably a shaft of the fan connected to a drive or motor arranged outside the box may pass through a shaft seal arranged on the housing, this shaft seal having a shaft gland which has a greater diameter than that of the shaft, and into which there opens out a radial line for feeding in a gas, preferably an inert gas such as nitrogen. In the particular case of the helical fan already mentioned, with a direction of its shaft and of its gas expulsion essentially parallel to the longitudinal direction of the magazine, the shaft of the helical fan preferably is connected by means of a magnetic coupling to a drive or motor arranged outside the box. These measures achieve the effect that the drive of the fan does not cause any leakage of the housing of the box, through which the gas could be contaminated from outside with air and dust or contaminants could escape with the gas to the outside. In the case of the shaft gland with inert gas, this gas washes around the shaft and then both enters into the interior space of the box and leaves the housing, so that no friction at all takes place on the shaft gland and, consequently, no bearing heat is generated; on the contrary, the shaft is cooled by the inert gas. In addition, the motors are arranged outside the box, so that damage to them by the considerable heat in the box is avoided, and also no mounting of the shaft of the motor can run hot.
On the box there is provided a feed line, by means of which firstly a fresh gas, for example an inert gas such as nitrogen or the like, can be introduced into the interior space of the box, for example in order to prevent oxidation of the parts of the lead frames. Then, on the box there is also provided a discharge line, by means of which the gas mixed with harmful subsfances can be conducted away from the interior space of the box. If, for example, a polymerization of epoxy resins is taking place, this gas should also be correspondingly disposed of.
Other designs for the baffles are also conceivable. In particular, it is possible to design the baffles as controllable shut-off plates or gates, so that here, in addition, more specific influencing of the gas stream can take place. However, the outlay is then also more considerable.
One aspect of the invention also relates to the door or the opening of the box. The main consideration here is for as little air as possible from the outside to be brought into the interior space of tile box when opening and closing the door, since this air is laden with dirt particles which could settle on the lead frames and would lead to disturbances, and, if appropriate, must be washed by an inert gas to avoid oxidation.
For this purpose, the door preferably is connected by means of a parallelogram linkage to a main housing supporting the box. This parallelogram linkage preferably comprise, in each case two levers, which are jointedly connected to the sides of the door and to the main housing and which can be moved by a drive. Between two levers there preferably is arranged an essentially horizontal crossmember, in which there is seated a sleeve with an internal thread, through which a fixed spindle rod passes. The spindle rod preferably is connected by means of a drive belt, to a motor.
Due to the fact that tile door is opened by a parallelogram linkage, it can be drawn away from the charging opening, for example downwards or upwards, without, as for example in the case of a hinged door, air being forced into the interior space of the box by slamming of the door. In addition, the seal between the box and the door is uniformly stressed, which ensures a better sealing and a longer serviceability of the seal.
The present curing installation has numerous advantages, which cannot in any way be completely enumerated individually. Due to the controlling and monitoring of virtually all process parameters, the maintenance of a very favorable temperature profile between the lead frames is possible, both with respect to heating and with respect to cooling. This is attributable in particular to the flow conditions chosen. The apparatus is suitable both for operation at high temperatures (for so-called snap curing) and allows treatment with inert gas. The electronic components are subjected to minimal stressing and only extremely low contamination. All the components are exposed at virtually the same time to the same curing conditions.
Moreover, the installation is not restricted to certain magazines, but, instead, various magazine sizes can be treated. Baffles do not have to be exchanged, nor do other precautions have to be taken. Effects of condensation on the chips or lead frames are ruled out.
Further points which should be emphasized are the compact type of design and the simple door mechanism. Such an installation can be integrated into an existing line in a simple and very favorable way.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention emerge from the following description of preferred exemplary embodiments and also with reference to the drawings, in which:
FIG. 1 shows a schematic plan view of an exemplary embodiment of a box according to the invention, in a curing system (not shown in any more detail) for lead frames which are fitted with electronic components;
FIG. 2 shows a schematic plan view of a further exemplary embodiment of a box for a curing installation corresponding to FIG. 1;
FIG. 3 shows a schematic plan view of a further exemplary embodiment of an opened box for a curing installation according to FIG. 1;
FIG. 4 shows a cross-section through the box according to FIG. 3;
FIG. 5 shows a partially represented cross-section through the box according to FIG. 3 along the line V--V;
FIG. 6 shows a side view of part of a curing installation having a integrated box;
FIG. 7 shows a plan view of the part of the curing installation according to FIG. 6;
FIG. 8 shows a plan view, represented partially broken, of a shaft seal according to the invention; and
FIG. 9 shows a cross-section through the shaft seal along the line IX--IX of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A box R for a curing installation for lead frames has, according to FIG. 1, a housing 1 closed on all sides, with a preferably vertical rear wall 2, preferably vertical side walls 3 and 4 and also a preferably vertical charging opening 5, which is defined by end edges 29 and is closed by a door 6.
In the box, R there is provided a magazine carrier 7a, on which a magazine 7 is set up centered approximately in front of the charging opening 5 and is consequently arranged approximately at medium height of the box R. Located in the magazine 7 are the lead frames to be treated, so that during one pass in a box R a plurality, for example 40, of such lead frames can be heat-treated in one operation.
The magazine carrier 7a is thermally coupled as well as possible to the magazine 7, but is thermally isolated from the housing 1. For example, the magazine carrier 7a is a cuboidal block of aluminum alloy which is supported on the housing 1 by means of a thermally insulating intermediate layer 7b, for example made of ceramic (cf. in FIG. 4). The magazine 7 is also made of aluminum alloy and its setting-up on the magazine carrier 7a accomplishes the desired thermal contact.
Essentially at the center of the magazine carrier 7a and thermally coupled to it, there is provided a temperature sensor 67c, which can be introduced into the magazine carrier 7a, for example via a duct 67d (cf. in FIG. 4). This temperature sensor 67c is, for example, a thermocouple or else a temperature-sensitive platinum resistor, or the like. By measuring the temperature of the magazine carrier 7a, the temperature sensor 67c makes it possible to control the temperature of the magazine 7 and of the lead frames to be treated.
Located inside the housing 1, is a heater 8, by which a gas in the interior space I can be heated. In the exemplary embodiment shown in FIG. 1, the heater 8 comprises two separately arranged horizontal-axis heating spirals 8a and 8b, which are located in front of and behind a fan 9. The fan 9 is arranged in the housing 1 approximately in the vertical center plane of the latter and its blades are mounted on a horizontal shaft 10, which rotates in (only schematically indicated) bearing blocks 11 and 12. The shaft 10 is connected by means of a magnetic coupling 13 to an external drive (not shown in any more detail).
It can be seen that the temperature sensor 67c is shielded by the magazine carrier 7a from direct heat irradiation by the heating spirals 8a and 8b of the heater 8.
Between fan 9 and magazine 7, there is also provided a baffle 14, which ensures a desired gas flow.
In the exemplary embodiment according to FIG. 1, gas is sucked in from the left by the fan 9 with correspondingly set blades, this gas sweeping through the heating spiral 8a. Furthermore, the fan 9 forces the gas to the right through the other heating spiral 8b, the baffle 14 forming a forced-flow duct 15, through which the gas stream must pass. Thereafter, this heated gas passes through the magazine 7 and the lead frames arranged therein, and is sucked to the left, again through a further forced-flow duct 16, into the region or space of the fan.
It has been found in practice that the gas flowing slowly through the magazine has only a low heat capacity, so that there is a considerable difference in heat at the gas inlet side in comparison with the gas outlet side. This results in an asymmetrical treatment of the lead frames, which is not desired. It is possible to compensate for this disadvantage by reversing the direction of rotation of the fan 9 at certain time intervals, so that the gas inlet side in the magazine 7 changes. This reversal of the direction of rotation may be performed, as already mentioned, for example with a periodicity of 10 to 30 seconds and preferably of 10 seconds. As a result, significantly better results have already been achieved.
In a further exemplary embodiment according to FIG. 2, in a box R 1 the heater 8 comprises only a single heating spiral, which is arranged between a radial fan 17 and the magazine 7. Between heater 8 and radial fan 17 there is also located a closed gas-conducting branch 18, the sides of which are adjoined by chamber walls 19 and 20. The radial fan 17 is assigned a motor 24.
The chamber walls 19 and 20 form, together with side walls 3 and 4 and with adjustable gates or adjustable shut-off plates 21a and 21b, an interior space I 1 . The shut-off plate 21a is assigned an actuating device 23a, and the shut-off plate 21b is assigned an actuating device 23b. With the aid of these actuating devices 23a and 23b, the respective shut-off plates 21a and 21b can be displaced between two positions, or gates can be adjusted between two positions, in which they close the interior space I 1 or release their respective duct 15a or 15b for a gas flow to the magazine 7. In the position represented in FIG. 2, the duct 15a is closed by the shut-off plate 21a, while the duct 15b is released by the shut-off plate 21b. Consequently, no gas flow passes from the duct 15a to the magazine, while a gas stream is passed via the duct 15b to the magazine 7. This gas stream then flows fully or partially through the magazine 7 and is sucked in again by the radial fan 17 through the gas-conducting branch 18 and the heater 8. By analogy with the preceding text and with equivalent reasons and advantages, the actuation of the shut-off plates or gates may be performed, for example, with a periodicity of 10 to 30 seconds, preferably of 10 seconds, in order to change alternately the gas inlet side at the magazine 7 and the direction of the gas stream through the magazine 7.
In the heater 8, there is, moreover, an additional temperature sensor 65 perspectively indicated. In fact, a tube sleeve 66 runs essentially coaxially with the heater 8. The tube sleeve 66 serves as a thermal shield and mechanical protection for a temperature sensor 67, corresponding connecting lugs 68 being lead out from the interior space I 1 of the box R 1 through an only partially represented small tube 69. The relative dimensions of the tube sleeve 66 and of the heating spiral of the heater 8 are chosen such that the temperature sensor 67 is shielded by the tube sleeve 66 from direct heat irradiation by the heating spiral of the heater 8. The additional temperature sensor 65 supplies an additional measured temperature value, by which the control of the spatial and temporal temperature profile in the box R 1 can be further improved. Such an additional temperature sensor 65 can be used in every exemplary embodiment of the present invention.
A further exemplary embodiment is shown in FIGS. 3 to 5. A housing 1a of a box R 2 is, in this case, of a polygonal design and its wall parts are filled with heat-insulating material 25. In the case of this housing 1a, its rear wall 2a is designed to be less wide than its charging opening 5. This charging opening 5 is formed by two approximately parallel-running side wall strips 3a and 4a, which are adjoined by side wall strips 3b and 4b which are bent off towards the rear wall 2a via a knee 26. In these side wall strips 3b and 4b, there are provided recesses 27 for receiving a motor 24a and 24b, respectively, each motor 24a and 24b driving a radial fan 17a and 17b in the interior of the housing la. It can be seen, in particular from FIG. 3, that neither of the motors 24a and 24b protrudes out of the outer plane of the housing 1a which is formed by the outer wall of the side strips 3a and 4a. Consequently, a plurality of such boxes R 2 can be arranged one next to the other and one above the other without hindering one another due to the arrangement of the motors 24a and 24b outside the boxes R 2 .
The arrangement of the motors 24a and 24b outside the box R 2 has considerable advantages, both for the motor itself, and for the mounting of a shaft 10a, on which the radial fan 17a or 17b is seated. Inside the housing 1a there are, as desired, high temperatures, which would have adverse effects on a motor. It is enough to disturb operation if the shaft 10a is significantly heated. In the present exemplary embodiment, such a hot mounting can be counteracted by corresponding insulating measures such as mounts 28 for the motor 24a or 24b.
A preferred exemplary embodiment of a shaft seal is shown in FIGS. 8 and 9. Such a shaft seal 70 comprises a washer 71, which has approximately in its center a shaft gland 72. The diameter d of the shaft gland 72 is greater than the diameter of the shaft 10a. As a result, the shaft 10a is mounted with play in the shaft seal 70. In the shaft gland 72, there opens out a radial line 73, via which an inert gas, for example nitrogen, is introduced into the shaft gland 72. This gas washes around the shaft 10a and effects a sealing of the interior space of the box R 2 to the outside and also to the inside. In addition, this washing-around of the shaft 10a effects its cooling by the gas. Corresponding teed lines for the gas are not shown in any more detail. Consequently, the shaft 10a can pass through the housing of the box R 2 without friction and nevertheless no leakage of the housing 1a of the box R 2 , by which the gas could be contaminated from outside with air and dust, is caused.
In addition, the end edges 29 of the side wall strips 3a and 4a are covered by a corresponding ring seal 30. For the reasons specified below, it is essential that the interior space of the housing 1a remain hermetically sealed. In the polymerization of epoxy resins, subsfances are released, so that the gas from the box should not be discharged into the environment, without cleaning or the like. Furthermore, it is imporfant that the treatment of the lead frames be performed as tree from dust as possible. In addition, generally an inflow of nitrogen, described later, is mixed in, in order to prevent undesired oxidation.
In the interior of the housing 1a, there run approximately parallel to the obliquely inclined side wall strips 3b and 4b respective walls 31a and 31b, which are supported by means of corresponding plates 32a and 32b against a bottom 33 of the housing. Inserted into each of these walls 31a and 31b, there is a respective gas-conducting branch 18 of the type already mentioned above in the case of another exemplary embodiment, which branch interacts with the corresponding radial fan 17a or 17b. There is advantageously also formed on the gas-conducting branch 18, an annular flange 34, which serves inter alia as a baffle and prevents return flowing of tile sucked-in gas into tile gas-conducting branch 18.
Since the wall 31 runs up to the rear wall 2a, there is formed between radial fan 17 and rear wall 2a a space 35, which is open only towards the radial fan 17. Otherwise, no gas flow in another direction can be produced here.
Between the two walls 31a and 31b, arranged obliquely with respect to each other, the heater 8 is arranged as an upright heating spiral, the helix axis M of which is arranged essentially orthogonally to the respective longitudinal axes A, B of the output branches 18. Longitudinal axis A and longitudinal axis B of the shafts 10a and 10b of the motors 24a and 24b preferably intersect at a center point M of the heater 8, or on the helix axis M of the corresponding heating spiral. The axes A and B also form, moreover, a center axis for the respective gas-conducting branch 18.
It can be seen in FIG. 4 that the heater 8 is connected with an energy source (not shown in any more detail) via corresponding connecting lines 36. Furthermore, there can also be seen in FIG. 4 a feed line 38 and a discharge line 39, which open out in the interior of the housing 1a close to a bottom 33 or a top 40, tile distribution of the fed-in gas and the collection of the gas to be discharged being assisted by a distributor plate 41 and a collecting plate 42, respectively. Fed in, for example, is preheated nitrogen. Discharged, in particular, is a gas which is charged with subsfances released during the polymerization of epoxy resins.
The major advantage of the present invention is firstly that as little gas deflection as possible takes place. A gas deflection always has an undesired pressure drop as a consequence, so that as few deflections as possible are to take place. In the present exemplary embodiment, the slight gas deflection at the knee 26 or in guide ducts 43 and 44 between wall 31a and side wall strip 3a and between walls 31b and side wall strip 4a, respectively, scarcely has a marked effect on the pressure of the flow. The gas then only has to be deflected respectively from both sides to the inlet into the magazine 7. If appropriate, this may be further improved by lateral chicanes (not shown in any more detail) in front of the magazine 7.
The idea of the invention also covers the notion that the motors 24a and 24b can turn, instead of in the same sense, also in the opposite sense, whereby however, a gas flow on both sides of the magazine 7 is intensified either in the tipper region or in the lower region, while the gas flow is reduced in the other region respectively. This results from the following consideration:
If, for example, the radial fan 17a is rotating clockwise, gas is centrifuged by the lower half of the impeller of the radial fan 17a rearwards into the chamber 35, or against the rear wall 2a. A delivery of gas through the guide duct 43 takes place, on the other hand, through the upper part of the impeller of the radial fan 17a. Consequently, the gas flow is accelerated in the upper housing region, so that a flow at the lead flames stored at the top in the magazine 7 is also intensified. The same explanation also applies to the radial fan 17b, provided that its motor 24b is turning counter-clockwise. Consequently, two intensified gas streams meet each other in the upper region of the magazine 7, while the lower region of the magazine is essentially neglected.
For this reason, both motors 24a and 24b are preferably caused to turn in the same sense. As a result, it is ensured that, in an upper region of the box R 2 , higher speeds of the gas flows in the one direction of throughflow (fan 17a with motor 24a) are compensated by somewhat lower speeds of the gas flows in the other direction of throughflow (fan 27b with motor 24b), while the converse of this applies in a lower region of the box R 2 and consequently, in the box R 2 there is produced a system of gas flows which, viewed through the vertical charging opening 5, appears to have a symmetry about the center and the diagonals (but not the center lines) of the recfangular charging opening 5.
Here, too, a periodic reversal of the direction of rotation of the motors leads to a changing distribution of the gas stream in the box R 2 , and, consequently, to an improvement in the handling of the lead frames. By analogy with the preceding text and with equivalent reasons and advantages, this joint reversal of the direction of rotation of the two fans may be performed, for example, with a periodicity of 10 to 30 seconds, preferably of 10 seconds, in order to change alternately the direction and distribution of the gas stream through the magazine 7. As in the case of the designs described above, here, too, in the box R 2 there is provided a magazine carrier 7a, on which a magazine 7 is set up centered approximately in front of the charging opening 5, and, consequently, is arranged at medium height of the box R 2 , in order for it to be subjected more uniformly to the gas stream. Here too, the magazine carrier 7a is thermally coupled as well as possible to the magazine 7, but is thermally isolated from the housing 1 or from its bottom 33 by means of the intermediate layer 7b (cf. in FIG. 4), and here, too, essentially at the center of the magazine carrier 7a and thermally coupled to it, there is provided a temperature sensor 67c, which can be introduced into the magazine carrier 7a via a duct 67d (cf. in FIG. 4), in order too make it possible, by measuring the temperature of the magazine carrier 7a, to control the temperature of the magazine 7 and of the lead frames to be treated. In this case, the temperature sensor 67c is shielded by the magazine carrier 7a from direct heat irradiation by the heating spiral of the heater 8.
In addition to the temperature sensor 67c, in the box R 2 there are provided two gas-temperature sensors 67a and 67b (cf. in FIG. 3), which are both arranged at medium height of the box R 2 , and, consequently, in relation to each other essentially at the same height approximately at the end of the walls 31a and 31b, in order to sense the temperature of the respective gas streams in the guide ducts 43 and 44. There may also be provided more than one such pair of gas-temperature sensors (cf. in FIG. 4), for example six gas-temperature sensors (of which only the three left-side gas-temperature sensors 67b', 67b" and 67b'" are visible in FIG. 4). Such gas-temperature sensors are then arranged in pairs in relation to each other essentially at the same height in the box R 2 , for example also at the end of the walls 31a and 31b. These additional gas-temperature sensors 67a and 67b allow, by means of their temperature, the symmetry of the gas streams in the box R 2 to be ascertained and subsequently the symmetry of the operation of the box R 2 to be monitored. In this way, the maintenance of the temperature profile at the components in the magazine can be ascertained best and can be monitored optimally.
Such gas-temperature sensors can also be used in conjunction with other designs of the invention, for example in order to ascertain, by means of their temperature, the symmetry of the gas streams in the forced-flow ducts 15 and 16 of the box R of the design according to FIG. 1 or in the forced-flow ducts 15a and 15b of the box R of the design according to FIG. 2.
It is beneficial for automatic charging of the box R if the door 6 can be opened fully automatically and removed entirely from the region of the charging opening 5. According to FIGS. 6 and 7, there is provided for this purpose a parallelogram linkage 45, by means of which the door 6 can be brought away from the charging opening 5 into an end position underneath the charging opening 5 close to a main housing 46 of the curing installation. This end position and an intermediate station are indicated by dashed lines in FIG. 6.
The parallelogram linkage 45 has two parallel-arranged levers 47 and 48, which on the one hand form a fixed pivot joint 49 with the box R above the main housing 46, while on the other hand they are connected by means of a further pivot joint 50 to the door 6.
The levers 48 are connected by means of pivot pins 51 to a crossmember 56, in which there is mounted a sleeve 52 which has an internal thread (not shown in any more detail). This internal thread meshes with a spindle rod 53, which is rotatably mounted and is connected with a motor 55, for example by means of a drive belt 54. The entire drive arrangement is tiltably mounted, so that allowance can be made for the movement of the parallelogram linkage 45, as is also represented by dashed lines.
In FIG. 7 it can be seen that the crossmember 56 can slide along guide columns 57. Laterally, the crossmember 56 is connected by means of corresponding pins 58 to the lower lever 48, both lever 48 and lever 47 moving in slots 59 in the main housing 46. In FIG. 7, it is indicated on the right that right next to one box there may be placed a further box.
With the aid of this parallelogram linkage, the door 6 can be moved in relation to the charging opening 5, the door 6 always remaining parallel to the plane of the charging opening 5, and consequently to the seal 30. During closing of the box, therefore, the seal 30 is compressed and stressed simulfaneously and uniformly over its entirety between the box and the door, which reduces the wear of the seal, and consequently improves the sealing, and also ensures longer serviceability of the seal. | In the case of a curing installation, in particular for magazines with lead frames which are fitted with electronic chips, there is provided at least one box (R 2 ) which can be closed by a door and in which at least one fan is arranged for subjecting the lead frames in the magazine to hot gas. The fan is supported on a housing of the box (R 2 ) and is arranged in such a way that it produces in the region of the magazine at least one essentially horizontally directed gas stream essentially parallel to the longitudinal direction of the magazine, so that gas flows through the magazine. The fan may be designed as a helical fan or a radial fan, and the direction of the gas stream may be varied by reversal of the direction of rotation of the fan. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/808,948 filed Apr. 5, 2013 which is incorporated by reference in its entirety as if set forth at length herein.
TECHNICAL FIELD
[0002] This disclosure relates generally to the field of computers and information systems and in particular to methods and structures pertaining to the reclamation of storage space such as found with a persistent cache.
BACKGROUND
[0003] Contemporary computer and information systems make extensive use of cache storage structures. As is known, cache must be managed such that portions of it are allocated to processes and/or programs at their request and freed for reuse when no longer needed. A form of management known as “garbage collection” attempts to reclaim cache memory occupied by objects that are no longer in use by the program. Given its importance to contemporary computer systems, improved garbage collection methods for cache systems would represent a welcome addition to the art.
SUMMARY
[0004] An advance in the art is made according to an aspect of the present disclosure directed to garbage collection in a persistent cache. Viewed from a first aspect, the present disclosure provides method(s) for managing the cache such that any applications utilizing the cache do not have to manage the particularities of cache garbage collection.
[0005] Operationally, the cache management/garbage collection method includes: tracking trees of objects in a live space, said trees in live space including one or more objects and a root object; tracking trees of objects in an orphan space, said trees in orphan space including one or more objects and no root object; moving any trees of objects in the live space to a new live space if those trees of objects do not include a root object that has been marked for deletion; reclaiming the space of any trees of objects having a root object marked for deletion.
[0006] Trees of objects according to the present disclosure are constructed from the bottom-up in the orphan space until a root object is associated with those objects. Advantageously, garbage collection is performed by the cache method, and therefore allows any short-lived objects to be released from the cache, without requiring them to be written through to an underlying store. Additionally, methods according to the present disclosure allow applications to use and subsequently delete trees of objects stored in a cache without having to delete all constituent objects in the tree when the tree of objects is no longer needed by the application.
BRIEF DESCRIPTION OF THE DRAWING
[0007] A more complete understanding of the present disclosure may be realized by reference to the accompanying drawings in which:
[0008] FIG. 1 shows in schematic form two trees of objects in a cache according to an aspect of the present disclosure;
[0009] FIG. 2 shows a flowchart depicting a WriteObject operation according to an aspect of the present disclosure;
[0010] FIG. 3 shows a flowchart depicting a DeleteRoot operation according according to an aspect of the present disclosure;
[0011] FIG. 4 shows a flowchart depicting a ReclaimObjects operation according to an aspect of the present disclosure; and
[0012] FIG. 5 shows a schematic block diagram of an illustrative computer system on which aspects of the present disclosure may be operated and/or executed.
DETAILED DESCRIPTION
[0013] The following merely illustrates the principles of the disclosure. It will thus be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the disclosure and are included within its spirit and scope. More particularly, while numerous specific details are set forth, it is understood that embodiments of the disclosure may be practiced without these specific details and in other instances, well-known circuits, structures and techniques have not been shown in order not to obscure the understanding of this disclosure.
[0014] Furthermore, all examples and conditional language recited herein are principally intended expressly to be only for pedagogical purposes to aid the reader in understanding the principles of the disclosure and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions.
[0015] Moreover, all statements herein reciting principles, aspects, and embodiments of the disclosure, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently-known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.
[0016] Thus, for example, it will be appreciated by those skilled in the art that the diagrams herein represent conceptual views of illustrative structures embodying the principles of the invention.
[0017] In addition, it will be appreciated by those skilled in art that any flow charts, flow diagrams, state transition diagrams, pseudocode, and the like represent various processes which may be substantially represented in computer readable medium and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
[0018] In the claims hereof any element expressed as a means for performing a specified function is intended to encompass any way of performing that function including, for example, a) a combination of circuit elements which performs that function or b) software in any form, including, therefore, firmware, microcode or the like, combined with appropriate circuitry for executing that software to perform the function. The invention as defined by such claims resides in the fact that the functionalities provided by the various recited means are combined and brought together in the manner which the claims call for. Applicant thus regards any means which can provide those functionalities as equivalent as those shown herein. Finally, and unless otherwise explicitly specified herein, the drawings are not drawn to scale.
[0019] Thus, for example, it will be appreciated by those skilled in the art that the diagrams herein represent conceptual views of illustrative structures embodying the principles of the disclosure.
[0020] By way of some additional background, it is noted that contemporary computer and information systems include memory and/or storage management systems that oftentimes utilize persistent caching mechanisms and structures to facilitate reading/writing from/to those memory and/or storage systems. The utility of such persistent caching mechanisms is well documented and understood.
[0021] As application programs execute on these computer systems they acquire portions of the cache and release it for reuse when no longer needed. More particularly—and by way of example only—application programs generally acquire portions of the cache to hold objects used during the execution of the programs. When the application terminates or the objects are no longer needed, the application releases those portions of the cache used to hold the objects. To insure that the requested/released cache is actually available for reuse, a form of cache management known as garbage collection attempts to reclaim cache memory occupied by objects that are no longer in use by the program.
[0022] Typically, a traditional garbage collection system and associated cache management strategy relies on being able to identify “live” and “dead” objects in the cache. More particularly, the garbage collection system ignores live objects (those objects still in use by the application), and frees the cache space used by all dead objects thereby making that space available in the cache for other application(s)/objects.
[0023] Turning now to FIG. 1 , there is shown in schematic form two trees of objects stored in a persistent cache according to an aspect of the present disclosure. The cache is persistent in that objects written to the cache persist in the cache and do not necessarily get immediately written back or written through to an underlying storage system. This advantageously allows the persistent cache to maintain its currency even during off-line periods.
[0024] With continued reference to FIG. 1 , it is noted that the persistent cache includes multiple objects that are stored as “trees”. More precisely, the objects are stored as directed acyclic graphs, or acyclic digraphs or “DAG”s, however we use the term tree because it is easier to visualize and trees are a subclass of DAGs.
[0025] As depicted in that FIG. 1 , the tree on the left has a root (R 1 ) and includes objects A, B, C, and D. Conversely, the tree on the right—comprising objects E, F, and G has no root.
[0026] Briefly, trees listed in a Live Space comprise objects that are considered “live” in that they may still be used by an application and have not been marked for deletion. Trees of objects listed in an Orphan List—as we shall see—are those under construction and as may be readily appreciated the storage space they occupy in the cache may not be reclaimed.
[0027] Operationally, an application marks or “tags” the root of trees that are to be deleted. Garbage collection according to the present disclosure tracks object trees in the Live Space combined with the Orphan List to determine what space may be reclaimed.
[0028] More specifically, the Orphan List maintains the list of child objects that are not yet reachable by a root (i.e., right tree in FIG. 1 ). As non-root objects are added to the cache, they are added to and tracked in the Orphan List.
[0029] When a root is added, any objects in that root's tree are moved from the orphan list to the Live Space and the root is added to a list of roots in the Live Space. When a tree is to be deleted, its root is tagged for deletion and the root is removed from the list of roots in the Live Space.
[0030] When the set of dead objects—those whose space may be reclaimed—is to be determined, we start with the live roots and copy all object trees they reference to a NewLive Space. Objects in the Orphan List are left alone—as they represent objects not yet part of any tree. As a result, objects remaining in the Live Space (Old Live Space) contains a list of all dead objects whose space in the cache may be reclaimed.
[0031] As may now be appreciated, while persistent cache systems and methods according to the present disclosure provide and support other operations, three in particular are of specific interest. More particularly:
WriteObject: writes an object to the cache. A flag distinguishes root objects from other objects. A list of child objects specifies which other objects, if any, this written object points to; and DeleteRoot: marks a root object as able to be deleted. This does not actually delete the object; and ReclaimObjects: reclaim the space occupied by all dead objects.
[0035] Turning now to FIG. 2 , there it shows a flow chart for the WriteObject operation. As shown therein upon entry to WriteObject a determination is made whether or not the object to be written is a root object. If it is not, then the object is added to the Orphan List and the operation ends. Conversely, if the object to be written is determined to be a root object, then that root object is added to the Live Root List and Live Space and descendents are copied from the Orphan List to the Live Space.
[0036] FIG. 3 shows a flow chart depicting the DeleteRoot operation. As shown there, upon entry to DeleteRoot the root object is removed from the live root list. As may be appreciated, when the DeleteRoot operation is performed the root is marked for deletion such that any cache space occupied by the tree of objects reference by the deleted root is now reclaimable.
[0037] FIG. 4 shows a flow chart depicting the ReclaimObjects operation according to an aspect of the present disclosure. More specifically, upon entry ReclaimObjects first obtains a root at the beginning of an old, live root list. If the list is not empty, then that root is moved to the list of roots in NewLive Space and any descendants referenced by that root are copied to the NewLive Space. That process continues with the next root in the old list until all (live) roots in the old list are moved and the end of the old list is reached.
[0038] Next, all objects remaining in the old live space are reclaimed (the storage they occupy in the cache is reclaimed) and the old live space and root list is replaced with the new live space and root list. Because objects in the Orphan List are not present in the live space, the orphan objects are not reclaimed.
[0039] As may be appreciated, with these three operations, applications (the user of the cache) provides information to the cache about which roots are no longer needed and can therefore be considered dead such that any space in the cache they occupy may be reclaimed. Objects that don't yet have a root (under construction) are hidden from the garbage collection operation such that their space is not reclaimed.
[0040] Advantageously, the persistent cache garbage collection method and structures according to the present disclosure is a hybrid one, wherein applications construct object trees in the cache while inserting objects in a bottom-up manner, and then tag or otherwise mark the roots of the object trees. When a tree of objects needs to be deleted, the application aids the garbage collection method by tagging the roots of trees that can be reclaimed. Accordingly, the garbage collection method then handles the detection of objects that may be deleted while avoiding any intermediate objects.
[0041] FIG. 5 shows in schematic form an exemplary computer system in which the methods and structures disclosed may be operated. Such exemplary computer includes at least a processor, memory and input/output components which may include cache and programs and systems that perform the operations disclosed.
[0042] Those skilled in the art will readily appreciate that while the methods, techniques and structures according to the present disclosure have been described with respect to particular implementations and/or embodiments, those skilled in the art will recognize that the disclosure is not so limited. Accordingly, the scope of the disclosure should only be limited by the claims appended hereto. | Disclosed herein are methods and structures for a computer cache that includes its own garbage collection component that reclaims space occupied by free objects in the cache such that the cache avoids retaining deleted objects thereby increasing cache hit ratios and further permits short-lived dirty objects to be deleted without requiring them to be written back to an underlying store. | 6 |
FIELD OF THE INVENTION
The field of this invention is jars for downhole use in operations such as drilling and fishing and more particularly to fluid operated jars that function bi-directionally.
BACKGROUND OF THE INVENTION
Jars are downhole devices that are used to impart a blow in an uphole or downhole direction to a stuck object. They have also been designed to impart rotary motion so that a drill bit can be turned as well as hammered during a drilling operation. There are the purely mechanical types that deliver a fixed jarring force triggered by pulling up on the string. There are hydraulic versions that generally have two telescoping members with fluid reservoirs annularly disposed in between. A small orifice through which the oil has to pass resists the initial pulling of the string. This passage is in a movable piston that isolates the two annular cavities as the pulling force is applied. Eventually, the movable piston with the orifice in it clears a narrow passage allowing oil to rush around it and allowing the telescoping members to contact each other to deliver a hammer blow to an anvil.
Yet other designs of jars have used the concept of valves in pistons, which when closed allow pressure buildup to move telescoping members with respect to each other and against the force of a spring. As more relative movement under these conditions occurs, the spring force eventually overcomes the hydraulic force holding the valve in the piston closed and the movement of the telescoping members is violently reversed. This results in a hammer blow delivered to an anvil as the tool reassumed the initial position for a repetition of the same cycle. A good example of this style of bi-directional jar is U.S. Pat. No. 5,803,182. While this design can hammer bi-directionally, it did not have the capability of also delivering rotary motion to a drill bit. Another example of a bi-directional hydraulic jar is U.S. Pat. No. 4,462,471.
Prior attempts to provide bit turning capability to jars involved the provision of a pin extending in a spiral slot to convert axial movement in the jar to a rotational output at the bit secures at its lower end. An example of this design is U.S. Pat. No. 4,958,691. It features the use of a plurality of tilting cams to insure rotation in a single direction for drilling. This tool did not have bi-directional capability and the mechanical reliability of the arrangement of the pin in the spiral slot was less than ideal.
The present invention addresses the limitations of the prior designs and seeks to accomplish a variety of objectives in a single tool, some of which will be enumerated. The jar of the present invention delivers bi-directional jarring capability in conjunction with the ability to impart rotational motion for drilling. The clutching system addresses the reliability issue in a drilling environment. Cushioning members reduce wear on valve seats from cyclical loading. Modularity allows for rapid conversion from bi-directional operation to unidirectional operation. Use of a singular spring system for jarring in opposite direction and other features allow reduction of overall length of the jar, in comparison to existing bi-directional jars. The number of parts is also reduced to aid the objective of reliability and overall length reduction. These and other objectives will be more apparent to a person skilled in this art from a review of the detailed description of the preferred embodiment described below.
Also relevant for background in the field of downhole jars are U.S. Pat. Nos. 4,076,086; 4,361,195; 4,865,125; 5,086,853; 5,174,393; 5,217,070; 4,462,471; 6,062,324; 6,035,954; 6,164,393; and 6,206,101.
SUMMARY OF THE INVENTION
A bi-directional jar with bit turning capability is disclosed. To jar down, weight is set down on the tool and pressure is built up on a piston to move the body up while compressing a spring. When spring force opens the valve in the piston, the housing comes down striking an anvil as the flow rushes through the piston before the valve recloses for another cycle. The valve member features a hydraulic brake to slow its movement after the valve is forced open. Clutching action comes from an angled spline acting through a spirally cut cylinder, which reduces in diameter to engage the bit to turn. A single spring acts on a pair of pistons for bi-directional jarring. Modularity allows rapid conversion to uni-directional operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a - 1 c are a sectional elevation of the jar in the run in mode or in the ready for up impact mode;
FIGS. 2 a - 2 c are the view of the jar in the ready for down impact mode;
FIGS. 3 a - 3 c are the position subsequent to FIGS. 2 a - 2 c after pressure buildup but before delivery of the downward jarring blow;
FIGS. 4 a - 4 c are subsequent to the position of FIGS. 3 a - 3 c with the valve open in the piston but prior to the delivery of the jarring impact;
FIGS. 5 a - 5 c are the up impact position shown in FIGS. 1 a - 1 c but after pressure buildup but before delivery of the upward jarring blow;
FIGS. 6 a - 6 c are the view of FIGS. 5 a - 5 c shown after the built up pressure is released and before delivery of the upward jarring blow; and
FIG. 7 is a perspective view of the clutch showing the spline drive;
FIG. 8 is a perspective of the helix housing showing the internal teeth in hidden lines.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 a - 1 c , the apparatus A has a top sub 10 to which a tubing string (not shown) of coiled or rigid tubing can be attached. Upper shaft 12 is secured to top sub 10 at thread 14 . A plurality of elongated slots 16 are aligned with the longitudinal axis of upper shaft 12 to allow flow in passage 18 to pass around valve member 20 when valve member 20 is off of upper seat 22 , as will be explained below. Impact cap 24 is secured to upper shaft 12 at thread 26 . An opening 28 is in the lower end of impact cap 24 . Upper seat 22 surrounds opening 28 inside of impact cap 24 . A shock-absorbing ring 30 is sandwiched between upper seat 22 and impact cap 24 . Ring 30 also surrounds the opening 28 in its position below upper seat 22 . Valve member 20 is slidably mounted in passage 18 and during the run in position can fall toward its ultimate position against upper seat 22 . It may stop short of upper seat 22 , but, for up jarring with tension applied to top sub 10 , fluid pressure in passage 18 will ultimately seat valve member 20 on upper seat 22 . During down jarring, slots 16 will permit flow to bypass valve member 20 through open opening 28 on impact cap 24 .
Mounted around upper shaft 12 is upper sub 32 . Upper sub 32 is connected to main barrel 34 at thread 36 . Main barrel 34 has an impact shoulder 38 (FIG. 1 b ) and a thread 40 to attach the helix housing 42 at its lower end. Helix housing 42 has an internal helix 44 , see FIG. 8, whose purpose will be explained below.
Within main barrel 34 is dart body 46 . Dart body 46 has a central passage 48 that terminates in one or more lateral outlets 50 . Surrounding dart body 46 are springs 52 and 54 . Spring perch 56 is supported off a shoulder on main barrel 34 and acts as the lower support for spring 52 . An upper flange 58 on dart body 46 rests on spring 52 during run in. Dart bushing 60 rests on another internal shoulder in main barrel 34 and supports the lower end of spring 54 . Mounted above spring 54 is trip bushing 61 . Trip bushing 61 is designed to move up into contact with spring perch 56 when upward movement of the main barrel 34 urges dart bushing 60 upwardly, as will be explained below. A carbide insert 62 acts as a lower valve member when disposed against seat 64 , as will be explained below. A series of openings 66 allow springs 52 and 54 to compress without fluid resistance of a pressure buildup in annular space 68 . A tappet 70 is secured at the top of passage 48 . Tappet 70 has an extending pin 72 around which flow can enter passage 48 through passage 74 in tappet 70 . During run in, valve member 20 rests on pin 72 . For up jarring, valve member 20 is seated against upper seat 22 . Ultimately, pin 72 will force valve member 20 off upper seat 22 to deliver an up jarring force, as will be explained below.
Also mounted in main barrel 34 is piston 76 , which supports impact ring 78 . Annular seat 80 surrounds passage 82 through piston 76 . Shock absorbing ring 84 supports annular seat 80 against shock from contact by carbide insert 62 , as will be explained below. Shaft 86 is connected to piston 76 at thread 88 . Shaft 86 continues passage 82 to the lower end 90 where a drill bit can be connected for drilling or where the apparatus A can be attached directly or indirectly to a stuck object downhole for up and/or down jarring blows.
A coil clutch 92 is disposed between helix housing 42 and shaft 86 . FIG. 7 illustrates a perspective view of coil clutch 92 . It has a central passage 94 so it can be mounted over shaft 86 . It has a helical spline 96 that meshes with helix 44 on helix housing 42 . FIG. 8 shows in dashed lines the internal helix or spline 44 that meshes with the helical spline 96 on coil clutch 92 . Referring again to FIG. 7, the coil clutch has a cylindrical body 98 that is spirally cut in one or more spirals 100 . When helix housing 42 moves up the meshing of helical spline 96 with spline 44 causes rotation of coil clutch 92 in a direction that tends to expand the diameter of the spiral 100 . What this does is prevent engagement of shaft 86 by spiral 100 . When the helix housing 42 comes back down, it turns the coil clutch 92 in the opposite direction causing the spiral 100 to constrict around shaft 86 . The downward motion of helix housing 42 , which is prevented from rotation on its axis by keying upper sub 32 to upper shaft 12 (keying feature not shown), through the engagement of splines 96 and 44 , imparts a rotation to the coil clutch 92 , now securely grabbing the shaft 86 . As a result, the shaft 86 rotates and eventually receives a downward jarring blow when impact shoulder 38 strikes impact ring 78 , as will be explained below.
Passages 102 prevent liquid lock in annular space 104 due to relative movement of the helix housing with respect to shaft 86 . Bushing 106 allows the shaft 86 to turn in helix housing 42 with reduced wear. Seals 108 seal between piston 76 and main barrel 34 to facilitate pressure buildup on piston 76 when carbide insert 62 has landed on it. Seals 110 seal between impact cap 24 and main barrel 34 .
The main parts now having been described, the operation of the tool will now be reviewed. To jar down and rotate shaft 86 , weight is set down on top sub 10 with the bit (not shown) attached at lower end 90 . As shown in FIGS. 2 a - 2 c , setting down weight allows pin 72 to displace valve member 20 from upper seat 22 and flow to bypass valve member 20 through slots 16 and out through opening 28 . Carbide insert 62 is advanced into close proximity of seat 80 or may even land on it. If contact is not made just from setting down, the onset of pressure into passage 18 will push carbide insert 62 into contact with seat 80 . Pressure builds on piston 76 which can't move down, so the pressure drives up main barrel 34 , as shown in FIGS. 3 a - 3 c . Pressure maintains the dart body 46 against piston 76 up to a point. Dart bushing 60 is moved up with main barrel 34 to compress spring 54 against a travel stop 55 supported from dart body 46 , only after stop 55 engages a shoulder 57 on dart body 46 . However, before that can happen, spring perch 56 compresses spring 52 against flange 58 on dart body 46 . Upward movement of helix housing 42 turns the coil clutch due to the meshing of splines 96 and 44 . When helix housing 42 moves up, spiral 100 does not grab shaft 86 so that the coil clutch simply turns with respect to shaft 86 .
At some point, depending on the set down weight on top sub 10 the force from springs 52 and 54 overcomes the fluid pressure on piston 76 and carbide insert 62 lifts up from seat 80 , as shown in FIGS. 4 a - 4 c . As a result of flow being re-established, main barrel 34 is propelled down and dart body 46 is propelled up. As dart body 46 is propelled up, its lateral outlets 50 are obstructed by dart bushing 60 . This obstruction acts as a fluid brake on the upward motion of dart body 46 , because the rate of fluid passing through dart body 46 is dramatically reduced. This fluid brake is more reliable than shock bumpers used in past designs and wear on the cycling parts is reduced. Meanwhile, the rapid downward motion of helix housing 42 spins the coil clutch 92 in a manner so as to constrict spiral 100 on shaft 86 . Since helix housing 42 is constrained against rotation around its longitudinal axis and at the same time it is engaged through the meshing of splines 44 and 96 and spiral 100 is gripping shaft 86 , a turning force is imparted to shaft 86 . At the end of the movement of the main barrel 34 , shoulder 38 delivers a downward jarring blow to impact ring 78 . The tool now resumes the position in FIGS. 2 a - 2 c for another cycle.
FIGS. 1 a - 1 c also show the position of the tool connected to a downhole stuck object (not shown) at lower end 90 and an upward pull applied through the tubing to top sub 10 . In this position, valve member 20 is on or near upper seat 22 . If valve member 20 is not on seat 22 , turning the pump on will drive it the rest of the way to contact. Pressure can now build on impact cap 24 , which moves in tandem with valve member 20 . As this is happening, the string (not shown) is being further tensioned as impact ring 13 moves away from shoulder 15 . Valve member 20 pushes down on pin 72 , which drives down dart body 46 to compress the springs 54 and 52 via stop 55 and flange 58 . Eventually springs 54 and 52 provide enough force to allow pin 72 to displace valve member 20 from seat 22 . Flow can resume through impact cap 24 and the tension held in the tubing string (not shown) connected to top sub 10 drives up top sub 10 , upper shaft 12 , and impact ring 13 mounted to it. Impact ring 13 hits shoulder 15 on upper sub 32 to deliver the upward jarring blow. From the position in FIGS. 6 a - 6 c the tool returns to the position of FIGS. 1 a - 1 c . It should be noted that stretching out the tool for an up jar, as shown in FIGS. 1 a - 1 c , puts the upper end 43 of helix housing 42 in contact with shoulder 45 on piston 76 so that the up jarring blow passes from impact ring 13 to upper sub 32 , to main barrel 34 , to helix housing 42 that is now shouldered on shoulder 45 to communicate the up jarring blow to the piston 76 .
Coil clutch 92 can be omitted from the apparatus A if it is to be used purely as a jarring tool and not for drilling. Doing this will eliminate the turning force applied to shaft 86 but it will still get the downward jarring blows when impact shoulder 38 hits impact ring 78 . The apparatus A is a modular construction that allows it to be configured for jar up only, jar down only, jar up and down with no rotation, or jar down with rotation. Higher wearing components are simply removed from the assembly before use to get the desired effect. To eliminate up jarring, valve member 20 is removed. To eliminate down jarring carbide insert 62 or/and seat 80 are removed. To eliminate rotation, coil clutch 92 is removed.
Apart from the modular nature of the apparatus A, it delivers rotational force in a more reliable manner than the pin following a spiral slot technique used in U.S. Pat. No. 4,958,691. The meshing of inclined splines 44 and 96 is a far stronger connection that can stand up to the high cycle rates experienced by the apparatus A. The clutching action is also significantly more reliable than the array of cams used in that same prior art patent. The coil clutch 92 can have its spiral 100 made from a coil spring, a braided weave that exhibits action akin to the well known finger trap, or from a cylinder that is helically cut by a variety of techniques one of which could be laser cutting. It can have a single or multiple helixes. The cylinder could be cut in other patterns, which respond to rotation in opposed directions by an increase or decrease in diameter. Different materials can be used for coil clutch 92 and surface treatments can also be incorporated to improve grabbing action upon constriction or engagement. Other ratchet mechanisms to obtain the clutching action for single direction rotation are also contemplated within the scope of the invention.
In another feature of the invention, a single spring can be used instead of coil springs 52 and 54 . Other spring types such as Belleville washer stacks, compartments with compressible gases and fluid chambers with controlled leakage rates can be used as the source that provides the force to allow flow to resume, setting the stage for a jar in the up or down direction. To reduce tool length, a single spring system or equivalent system acts as the force to allow flow to resume, whether jarring in the up or the down directions. This is to be compared to other tools such as the jar tool shown in U.S. Pat. No. 5,803,182 that requires discrete springs for the jar up valve and the jar down valve, thereby adding complexity and length to the tool.
The apparatus A features shock absorbing rings 30 and 84 which can be made from a variety of metallic and non-metallic materials compatible with the anticipated temperature and fluid conditions found for the particular application. The rings can be solid or in segments and can have a variety of cross-sectional shapes. Their purpose is to absorb shocks on their respective seats 22 and 64 from the frequent cycling experienced in these types of jars. These rings are not the only form of shock absorbers in the apparatus A. The dart body 46 is accelerated upwardly during down jarring when the carbide insert 62 lifts off seat 64 . Rather than having such rapid acceleration stopped by repeatedly striking a fixed object, as depicted for example in U.S. Pat. No. 4,958,691, the apparatus of the present invention uses the rushing fluid through the dart body 46 as a hydraulic brake, as openings or lateral outlets 50 become temporarily obstructed by dart bushing 60 to rapidly decelerate the dart body 46 as it approaches impact cap 24 . There need not be a collision of these parts before a return of the dart body 46 to the neutral position. Wear on the parts from cyclic impacts is reduced, if not totally eliminated. It should be noted that other materials could be used for valve action instead of carbide, as mentioned for insert 62 without departing form the invention. The apparatus A can be used with or without known designs of accelerators, typically used with jars in shallow depths.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention. | A bi-directional jar with bit turning capability jars down when weight is set down on the tool and pressure is built up on a piston to move the body up while compressing a spring. When spring force opens the valve in the piston, the housing comes down striking an anvil as the flow rushes through the piston before the valve recluses for another cycle. The valve member features a hydraulic brake to slow its movement after the valve is forced open. Clutching action comes from an angled spline acting through a spirally cut cylinder, which reduces in diameter to engage the bit to turn. A single spring acts on a pair of pistons for bi-directional jarring. Modularity allows rapid conversion to uni-directional operation. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to pumps of the type used for introducing controlled amounts of a reagent into a process stream. These devices are typically referred to as chemical injectors and are used in a variety of manufacturing facilities for introducing metered amounts of fluid into another fluid stream, typically small amounts of a reagent into a process stream. One such chemical injection system is shown in U.S. Pat. No. 4,370,996, which system includes a gas powered timing relay and an injector pump, with the timing relay providing gas under pressure at controlled intervals for actuating the pump. Typically the pumps are controlled by such timing relays, and one such relay is shown in said U.S. Pat. No. 4,370,996, and another timing relay is shown in U.S. Pat. No. 4,465,090.
The reagents with which the injector pumps are used often are highly toxic or caustic or corrosive material, and often have strong odors. The caustic and corrosive materials tend to damage the pumps and hence it is desirable to avoid any contact between the reagent and the pump mechanism. Also, it is desirable to avoid leakage of the toxic materials and materials with strong odors, as well as leakage of the caustic and corrosive materials. In general, two types of pumps have been used in the past.
In one type of pump, the process stream is introduced into a pump chamber through a first check valve and exits from the pump chamber through a second check valve, with the pumping action being obtained by a positive displacement plunger which reciprocates in the pump chamber. With this type of construction, the plunger is in direct contact with the reagent, and seals are provided about the plunger for limiting leakage of the reagent along the plunger into the pump mechanism. High pressure seals are required in this type of pump, with a high back pressure in order to reduce the leakage. However, the reagent being in direct contact with the seals severely limits the effective operating life of the seals.
Typical pumps of this type include the Williams Instrument Company, Inc. Chemical Injector Models P250D and P500D and the Morgan Products Chemical Injector Models 50DS through 550DS.
Another type of injector pump or controlled volume pump utilizes an impermeable diaphragm between the pump plunger and the pump chamber, with movement of the pump plunger or piston causing movement of the diaphragm and hence obtaining the pumping action. Since this is a positive displacement type of pump, some type of bypass configuration is required in order to obtain the diaphragm displacement without damage to the diaphragm. This is achieved in existing pumps by means of a complex fluid bypass passage and valve system.
One such configuration is shown in U.S. Pat. No. 3,149,469, and one such diaphragm pump is produced by the Milton Roy Company as a Controlled Volume Pump.
It is an object of the present invention to provide a new and improved injector pump which will pump metered amounts of fluid for introduction into a process line, which pump incorporates a diaphragm or other impermeable member isolating the pumped material from the pump mechanism. A further object of the invention is to provide such an injector pump which is operable with the impermeable member without requiring any fluid bypass valving configuration for obtaining pump operation.
It is a further object of the invention to provide such an injector pump which can utilize various types of impermeable members, including diaphragms, bellows and Bourdon tubes. An additional object is to provide such an injector pump which can be operated with a single gas pressure inlet, or with dual gas pressure inlets for reciprocating motion, or with mechanical type drives.
Other objects, advantages, features and results will more fully appear in the course of the following description.
SUMMARY OF THE INVENTION
An injector pump for introducing metered amounts of fluid into a process line and the like, including a flexible and fluid impermeable member mounted in a housing to define a pump chamber and a piston chamber in the housing. A piston is positioned in the piston chamber, with a piston plunger sliding in a plunger guide carried in the piston chamber, with the plunger defining a pressure chamber between the plunger and the impermeable member. A high pressure seal is carried in the plunger guide with the plunger sliding in the seal, and some means is provided for moving the piston toward and away from the impermeable member. The high pressure seal leaks fluid along the plunger when the fluid between the plunger and the impermeable member is under low pressure providing a low pressure across a high pressure seal. Conversely, the high pressure seal seals about the plunger to prevent fluid leakage along the plunger when the fluid between the plunger and the impermeable member is under high pressure which results from movement of the piston plunger toward the impermeable member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view through an injector pump incorporating the presently preferred embodiment of the invention;
FIG. 2 is an enlarged partial sectional view of the pump of FIG. 1 illustrating one form of high pressure seal;
FIG. 3 is a partial sectional view similar to that of FIG. 1 showing an alternative construction for the pump chamber;
FIG. 4 is a partial sectional view similar to that of FIG. 1 showing the use of a bellows in place of the diaphragm;
FIG. 5 is a partial section view similar to that of FIG. 4 showing a Bourdon tube in place of the diaphragm; and
FIG. 6 is a sectional view of an injector pump similar to that of FIG. 1, but being powered in both directions by gas under pressure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The injector pump in the embodiment illustrated in FIG. 1 includes a housing formed with a plurality of components comprising a base 11, a sleeve 12, a top 13, and a ring 14. A diaphragm 15 and a piston plunger guide 16 are clamped between the sleeve 12 and base 11 by the threaded engagement of the sleeve with the base. Conventional O-rings 17, 18 are installed prior to assembly. The diaphragm 15 is a flexible and fluid impermeable member which may be of conventional construction.
A piston plunger 20 is threaded into a piston 21 and held in place by a lock nut 22. A spring 23 is positioned about the plunger 20 within the sleeve 10. The piston 21 carries a seal 24 for slidingly sealing with the inner wall of the housing sleeve 12.
The housing top 13 is held in place on the sleeve 12 by the threaded engagement of the cap 14 with th upper end of the sleeve, with an O-ring seal 27 therebetween. A threaded shaft 28 is threadedly engaged with the top 13, and is locked in place by another lock nut 29, with another O-ring seal 30 about the shaft.
A high pressure seal 33 and a back up ring 34 are carried in a cavity in the plunger guide 16, with the seal and ring being held in place by a cup 35 threaded onto the upper end of the plunger guide 16.
This assembly provides a pump chamber 38 in the housing base 11 which is separated from the pressure chamber 39 by the diaphragm 15. The diaphragm and the lower end of the piston plunger 20 serve to define the pressure chamber 39. The piston 21 slides in the piston chamber 40 of the housing.
An inlet check valve 43 and an outlet check valve 44 are mounted on the housing base 11 to provide for fluid flow into and out of the pump chamber 38, respectively. In the embodiment illustrated, the housing base 11 includes a plate section 45 positioned adjacent the diaphragm 15, with the plate having a plurality of apertures 46 for free flow of fluid from one side of the plate section to the other. The plate section provides strength while making the base 11 easier to manufacture.
The housing top 13 includes a boss 48 with a passage 49 therein for providing communication between the exterior of the housing and the piston chamber above the piston. A plug 50 is threadedly mounted in the sidewall of the sleeve 12 and has one or more openings so as to serve as a breather or vent for the piston chamber. A container 51 is carried on another plug 52 also threadedly mounted on the wall of the sleeve 12. A bleeder plug 53 for the pump chamber 38 is threadedly mounted in the housing base 11.
In operation, the reservoir 51 is filled with a liquid, typically an inert oil, so that the lower portion of the piston chamber is filled with the oil. The spring 23 moves the piston upward to engage the top 13 or the lower end of the shaft 28, with the shaft being rotatable to move the lower end up and down and thereby limit the length of the stroke of the piston, and thus control the amount of reagent pumped with each stroke. When gas under pressure is introduced at the passage 49, the piston is moved downward, compressing the spring 23. When the gas pressure is released, the spring moves the piston back upward to the position of FIG. 1. Typically the timing of operation, that is, the rate of piston strokes, is controlled by an air relay of the type previously identified.
When the piston plunger 20 moves downward, the liquid in the pressure chamber 39 moves the diaphragm 15 downward forcing reagent from the pump chamber 38 outward through the check valve 44. When the piston plunger 20 moves upward, the diaphragm returns to the normal position shown in FIG. 1, and reagent is sucked into the pump chamber 38 through the ckeck valve 43.
When the piston plunger 20 starts moving downward, there is a relatively low pressure on the liquid on the pressure chamber 39. Under this condition, the high pressure seal 33 permits leakage of the liquid upwardly along the plunger into the piston chamber 40. However, as the plunger continues to move downward, pressure in the pressure chamber increases, and the high pressure seal functions to provide a seal about the plunger and thereby retain the remaining liquid in the pressure chamber. Then further plunger movement moves the diaphragm 15 downward. Similarly, when the plunger starts moving in the upward direction, there is a reduction in pressure in the pressure chamber 39 and the high pressure seal again leaks, with liquid now moving downward along the plunger from the piston chamber 40 into the pressure chamber 39. The leaking action of the seal 33, while being very slight, causes the volume of liquid in the pressure chamber 39 to be self regulating, so long as there is a blanket of the liquid above the seal 33.
The piston operates at very low pressures, typically in the range of about 10-100 psi, although there is no theoretical limit. The lower limit is determined by the amount of pressure required to move the piston and the upper limit by the pressure which the structure will withstand. The significant characteristic here is that the sealing operation and the pumping operation is achieved without requiring any particular back pressure in the piston chamber. The pumped reagent typically under a higher pressure, usually in the range of about 300-1500 psi. However, again here there is no particular limit for the lower range or the upper range. The upper limit on the pressure of the pump reagent is the rupture strength of the impermeable member.
The high pressure seal 33 is a conventional unit and typically is designed for operation in the range of 10,000-100,000 psi. It has been determined that this type of seal will leak at relatively low pressures, and in the preferred embodiment of the present invention, seals desirable leak at pressures in the range of about 10-100 psi. Here again, these are not specific limitations and an injector pump could be operated satisfactory with a high pressure seal which leaked at pressures as high as 300 psi.
In operation, the high pressure seal leaks fluid along the plunger when the fluid between the plunger and the impermeable member is under low pressure which provides a low pressure across the high pressure seal. This condition exists when the plunger is at rest, and when the plunger initially starts its downward movement. However, the high pressure seal provides a fluid tight seal with a fluid tight sliding seal about the plunger for preventing fluid leakage along the plunger when the fluid in the pressure chamber is under high pressure which results from movement of the piston toward the impermeable member. As stated above, this operation is achieved without control of the back pressure in the piston chamber or control of pressure in the pump chamber, and without requiring any bypass passages and valving.
The high pressure seal 33 may be a conventional commercial product, and several are available on the market. One such seal is shown in greater detail in FIG. 2. The seal includes a seal ring 56 formed of a resilient material having no elastic memory, typically a graphite filled Teflon synthetic. The ring 56 has a U-shaped cross-section with the open end of the U at one end of the ring. The seal is installed with this open end facing the high pressure source, which is the pressure chamber 39 in the configuration of FIG. 1. Preferably a stiffner ring 57 is positioned within the seal ring 56 for the purpose of preventing the two arms of the U-shaped cross-section from collapsing toward each other.
In operation, the fluid under pressure will move upward along the plunger 20 and into the open portion of the U-shaped cross-section, thereby forcing the arms of the U outward into sealing engagement with the plunger and with the plunger guide. However, this sealing action does not occur at low pressures, and hence there is leakage along the plunger until pressure has built up.
These high pressure seals are available from a number of sources, including the Bal-seal from Bal Seal Engineering Company, the RSA Seal from Green, Tweed, the OMNI SEAL from Aeroquip Corporation, the Variseal M from American Variseal Corp. and the Raco Seal from Fluorocarbon Co.
An alternative construction for the embodiment of FIG. 1 is shown in FIG. 3, wherein the plate 45 is replaced by a porous disc 58. This porous disc may be of conventional construction, and one such device is available on the market as a disc comprising a plurality of metal balls sintered together. This type of porous disc is used as a filter and provides a strong mechanical construction which will withstand high pressures, and at the same time provide adequate fluid flow therethrough. Another suitable porous disc is a section of wire mesh or screen cut to the appropriate shape.
Another alternative configuration is shown in FIG. 4, where the diaphragm 15 is replaced by a bellows 16. The bellows functions as a flexible and fluid impermeable member in the same manner as the diaphragm, with the interior of the bellows providing a portion of the pressure chamber 39. When the plunger moves downward the liquid in the pressure chamber 39 causes the bellows to expand and exhaust reagent from the pump chamber 38. Similarly an upward movement of the plunger causes the bellows to retract and draw reagent into the pump chamber.
Another embodiment is shown in FIG. 5, with a Bourdon tube 61 used in place of the bellows 60. The operation is the same, with the Bourdon tube changing cross-section shape from elliptical toward circular, thereby increasing the volume of the interior of the Bourdon tube and reducing the remaining volume of the pump chamber.
Another alternative of the embodiment is shown in FIG. 6, where the piston 21 is moved both upward and downward by gas under pressure. The housing is constructed somewhat differently, including a base 70, a clamp ring 71 attached to the base 70 by bolts 72 and holding the diaphragm 15 in place, a plunger guide 73, a sleeve 74, a cylinder 75 and a top 76, with the top, cylinder, sleeve, plunger guide and clamp ring joined by threaded engagement, with O-ring seals therebetween. In this housing the plate 45 is formed separately from and is positioned within the base 70. The high pressure seal 33 and seal ring 34 are clamped between the sleeve 74 and the plunger guide 73.
In this embodiment, the piston plunger 20 is attached to the piston 21 by a bolt 63. A fitting 64 provides for gas flow into and out of the upper portion of the piston chamber 40 and another fitting 65 provides for gas flow into and out of the lower portion of the piston chamber. Hence gas under pressure introduced at fitting 64 moves the plunger downward, and gas under pressure at the fitting 65 moves the plunger upward.
The vent plug 50 and oil reservoir plug 52 are mounted in the housing sleeve 74 opening into an annular zone 67 defined by the seal 33 and another seal 68. The seal 68 is a low pressure seal for sealing the lower portion of the piston chamber when gas under pressure is introduced to move the piston upward. The operation of the injector pump of FIG. 6 is the same as that described for the injector pump of FIG. 1. While the pumps as illustrated are operated by gas under pressure, it is readily understood that the piston plunger could be moved by a mechanical drive which would replace the adjustable stop shaft 28. | An injector pump for introducing metered amounts of fluid into a process line which pump typically is actuated by a gas powered timing relay. A diaphragm or other impermeable member mounted in the pump housing defining a pump chamber for the fluid to be pumped and a piston chamber for a piston having a plunger sliding in a plunger guide to define a pressure chamber between the plunger and the diaphragm. A high pressure seal is carried in the plunger guide to provide sealing about the plunger when there is a high pressure in the pressure chamber, while permitting leakage along the plunger when there is a low pressure in the pressure chamber, thereby providing for pumping of measured amounts of fluid which may be under high pressure and/or highly corrosive, while maintaining isolation between the pump mechanism and the fluid. | 5 |
BACKGROUND OF THE INVENTION
[0001] Technical Field
[0002] The present invention generally relates to a material handling apparatus and, in an embodiment thereof, more particularly relates to an excavating apparatus, such as a skid steer, having lift arms connected to a specially designed bucket having a deployable breaker assembly internally mounted within the bucket, which uniquely permits the skid steer operator to selectively carry out both digging and breaking refusal material operations without having to change out equipment on the stick. The device is also applicable for use with other front loader machines.
[0003] Description of Related Art
[0004] Small scale earth excavation operations are typically performed using a powered excavating apparatus, such as a front loader or a skid steer, having a pair of lift arms connected to a hydraulically pivotal bucket or other excavating tool. The operator can use the bucket to forcibly dig into the ground, scoop up a quantity of dirt, and move the scooped up dirt quantity to another location.
[0005] A first common occurrence during conventional digging operations is that the bucket strikes refusal material (in excavation parlance, a material which “refuses” to be dug up) such as rock which simply cannot be broken and scooped up by the bucket, such as encountered in road work and driveway replacements.
[0006] A previously utilized alternative to this single skid steer sequence is to provide two excavators for each digging project—one excavator having a bucket attached, and the second excavator having a breaker attached. When the bucket-equipped excavator encounters refusal material during the digging process, it is moved away from the digging site, and the operator climbs down from the bucket-equipped excavator, walks over to and climbs up into the breaker-equipped excavator, drives the breaker-equipped excavator to the digging site, and breaks up the encountered refusal material. Reversing the process, the operator then switches to the bucket-equipped excavator and resumes the digging process to scoop up the now broken-up refusal material.
[0007] While this digging/breaking technique is easier on the operator, it is necessary to dedicate two large and costly excavators to a given digging task, thereby substantially increasing the total cost of a given excavation. A modification of this technique is to use two operators—one to operate the bucket-equipped excavator, and one to operate the breaker-equipped excavator. This, of course, undesirably increases both the manpower and equipment cost for a given excavation project.
[0008] An alternative to a second excavating machine is to employ the use of a man-operated jackhammer. In either case, progressing through the refusal material requires a second operator to maintain efficiency of the operation. This increases the cost of the operation by requiring a second operator and rental of a second excavating machine or pneumatic hammer. If a second operator is not used, then the operation requires the single operator to be proficient in the operation of both pieces of equipment. This procedure further requires that the operator safely stop the skid steer and exit the vehicle, move to the second vehicle or jack hammer, and begin its use. This procedure is predictably slow and exhausting for the operator.
[0009] This problem also arises during the operation of backhoe excavating machines. Recently, a commercially successful solution to at least part of this problem is disclosed in U.S. Pat. No. 6,430,849, U.S. Pat. No. 6,751,896, U.S. Pat. No. 7,117,618 and U.S. Pat. No. 7,257,910 (collectively, “the '849 patent family”). The '849 patent family discloses the Bayonet® Breaker System which provides an excavating machine known as a back-hoe with a specially designed pivotal boom stick assembly that includes a boom stick having first and second excavating tools secured thereto for movement relative to the boom stick. The first excavating tool is an excavating bucket secured to the boom stick for pivotal movement relative thereto between a first position and a second position, and the second tool is a breaker secured to the boom stick for pivotal movement relative thereto between a stowed position and an operative position.
[0010] As described in the '849 patent family, the bucket is operable when the breaker is in its stowed position. The bucket is movable by the drive apparatus independent of the breaker, to perform a digging operation. The breaker is operable when the bucket is in a first “stowed” position, which is away from the deployed position of the breaker to prevent contact and interference. The breaker is movable by the drive apparatus independent of the bucket, to perform a breaking operation. Accordingly, the excavating machine may be advantageously utilized to perform both digging and breaking operations without equipment change-out on the boom stick.
[0011] However, this solution is inapplicable to front loaders and skid steers that lack a boom stick for storage and deployment of the hammer without interfering with the operation of the bucket. Front loaders and particularly skid steers have a pair of lifting arms pivotally connected to a position behind the operator, and raise the bucket close to the operator's cabin. As a result, the operation of the skid steer is very different than that of a backhoe, and it lacks the flexibility in the movement of the arms that the boom stick on a backhoe enjoys, and is more suited for smaller jobs and operations in confined space.
[0012] The present invention is contrary to conventional design principals of the prior art, in which the volume of the bucket is maximized. Availability of the full volume of the bucket is necessary to maximize the carrying capacity of the bucket and thus reduce the time on the job. However, this long-held belief ignores the significant loss of time that occurs when the bucket encounters refusal material. When the surface rock is hard, the full capacity of the bucket is no longer the project time controlling constraint. Breaking the refusal material is.
SUMMARY OF THE INVENTION
[0013] In carrying out principles of the present invention, in accordance with one embodiment thereof, an excavating machine, representatively a skid steer, is provided with a pair of pivotal loader arms with a specially designed bucket having a deployable hammer located interior to the bucket, beneath a shield, and deployed through a portal passage in the base of the bucket. The loader arms position both the bucket and the deployed hammer above the refusal material, whereupon the hammer is actuated. When the refusal material has been fragmented, the hammer is retracted into the stowed position within the bucket. The bucket is then used to scoop and remove the fragmented material, thereby exposing virgin surface for digging or hammering.
[0014] Accordingly, the excavating machine may be advantageously utilized to perform digging and breaking operations without equipment change of the bucket or use of a jackhammer or other secondary excavating machine.
[0015] In one embodiment, a bucket-breaker assembly is disclosed for use on an excavating machine. A bucket is pivotally connected to the ends of the loader arms of the excavating machine, and is pivotally movable on a first axis relative to the loader arms. The bucket has an interior and an exterior. A breaker assembly is pivotally connected to the bucket, and is movable between a retracted position substantially internal to the bucket, and a deployed position substantially external of the bucket.
[0016] In another embodiment of the bucket-breaker assembly, a bucket is pivotally connected to the ends of the loader arms of the excavating machine, and is pivotally movable on a first axis relative to the loader arms along a first axis. The bucket has an interior and an exterior. A breaker assembly is pivotally connected to the bucket, and movable between a retracted position and a deployed position, with the movement of the breaker assembly being along a second axis that is substantially perpendicular to the first axis defining the movement of the bucket relative to the loader arms. The breaker assembly is actuated from the deployed position to operate the hammer.
[0017] In another embodiment of the bucket-breaker assembly, a bucket is pivotally connected to the ends of the loader arms of the excavating machine, and is pivotally movable on a first axis relative to the loader arms. The bucket has an interior and an exterior. A passage is formed on the bucket, and extends between the interior and exterior of the bucket. A breaker assembly is pivotally connected at a breaker pivot located on the interior of the bucket. The breaker assembly is pivotally movable between a retracted position substantially internal of the bucket and a deployed position through the passage formed in the bucket.
[0018] In another embodiment, the bucket-breaker assembly further includes a latch attached to the interior of the bucket. The latch is operable to secure the breaker assembly in the retracted position inside the bucket.
[0019] In another embodiment, the bucket-breaker assembly further includes a shield mounted to the interior of the bucket. In another embodiment, the shield substantially covers the breaker assembly when the breaker assembly is in the retracted position. In another embodiment, the shield substantially covers the passage between the bucket interior and the bucket exterior.
[0020] In another embodiment, the bucket-breaker assembly further includes a flange mounted to the interior of the bucket. The breaker pivot connection is attached to the flange. A shield substantially covers the passage between the bucket interior and the bucket exterior.
[0021] In another embodiment, the bucket-breaker assembly further includes a portal located on the shield. The portal is accessible from the interior of the bucket to permit adjustments to the breaker assembly. In another embodiment, the excavating machine is a skid steer.
[0022] The advantage of the disclosed embodiments is that they provide additional and critical utility to a single excavating machine. Specifically, the excavator operator may uniquely and selectively carry out multiple operations, including digging and breaking of refusal material without having to change out equipment on the skid steer, and without the need for a second excavating machine or independently operated jack hammer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a simplified, side view of a representative excavating machine conventionally known as a skid steer, having a bucket and breaker combination, illustrating the breaker in the stowed position.
[0024] FIG. 2 is a view of the excavating machine of FIG. 1 , illustrating the breaker assembly deployed and extending through the bottom of the bucket.
[0025] FIG. 3 is a side view of the bucket of the excavating machine of FIG. 1 , illustrated with the breaker assembly in the stowed position inside the bucket.
[0026] FIG. 4 is a front view of the bucket, with the breaker assembly in the stowed position inside the bucket, illustrated with the breaker shield removed.
[0027] FIG. 5 is a side view of the bucket, illustrated with the breaker assembly in the deployed position and extended beneath the bucket.
[0028] FIG. 6 is front view of the bucket, with the breaker assembly in the deployed position, illustrated with the breaker shield removed.
[0029] FIG. 7 is a perspective view of the bucket, illustrated with the breaker assembly in the stowed position and covered by the breaker shield.
[0030] FIG. 8 is a side view of the breaker assembly, illustrated in the stowed position.
[0031] FIG. 9 is a side view of the shield.
[0032] FIG. 10 is a perspective view of the breaker assembly, illustrated in the stowed position.
[0033] FIG. 11 is a bottom perspective view of the breaker assembly, illustrated in the stowed position.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Refer now to the drawings wherein depicted elements are, for the sake of clarity, not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0035] FIG. 1 is a simplified, side view of a representative excavating machine 1 , which is a skid steer. Excavating machine 1 has a body 2 and a pair of loader arms 4 pivotally connected to body 2 . The loader arms are controllable by the operator of excavating machine 1 .
[0036] A bucket-breaker combination 10 is pivotally connected to the ends of loader arms 4 at pivot connections 14 . Bucket-breaker combination 10 includes a bucket 12 , and a breaker assembly 40 affixed inside bucket 12 . In this FIG. 1 , breaker assembly 40 is in a stowed position, not visible. Bucket 12 is pivotally connected to loader arms 4 , and rotatable along an arc A in a first plane substantially parallel to the plane of FIG. 1 .
[0037] FIG. 2 is a side view of excavating machine 1 of FIG. 1 , illustrating breaker assembly 40 of bucket-breaker combination 10 in a deployed position and extending through a passage 16 on a bottom 18 (see FIG. 7 ) portion of bucket 12 . Breaker assembly 40 has a pivotal connection 42 (see FIG. 4 ) located inside bucket 12 . Breaker assembly 40 rotates a hammer 50 between a stowed position substantially interior to bucket 12 and a deployed position in which the hammer 50 is extending through passage 16 on bottom 18 of bucket 12 . Breaker assembly 40 is rotatable along an arc B in a second plane perpendicular to the first plane.
[0038] In the deployed position, hammer 50 is hydraulically operable to engage and fragment refuse material so that it may be removed using the bucket 12 with the breaker assembly 40 in the stored position.
[0039] FIG. 3 is a side view of bucket-breaker combination 10 of excavating machine 1 of FIG. 1 , illustrated with breaker assembly 40 in the stowed position inside bucket 12 . FIG. 4 is a front view of bucket-breaker combination 10 of excavating machine 1 , with breaker assembly 40 in the stowed position inside bucket 12 . For visibility, in this view there is no shield covering breaker assembly 40 . Bucket 12 has a bottom portion 18 (see FIG. 7 ). A passage 16 is formed on bottom portion 18 to permit the passage of breaker assembly 40 when it is rotated into the deployed position.
[0040] FIG. 5 is a side view of bucket-breaker combination 10 of excavating machine 1 , illustrated with breaker assembly 40 in the deployed position, extending a hammer 50 component of breaker assembly 40 through passage 16 and beneath bucket 12 . As shown in FIG. 1 and FIG. 5 , bucket 12 rotates along arc A in a first plane. As shown in FIG. 2 and FIG. 5 , breaker assembly 40 rotates along arc B in a second plane that is perpendicular to arc A and the rotation of bucket 12 .
[0041] FIG. 6 is a front view of bucket-breaker combination 10 of excavating machine 1 , illustrated with breaker assembly 40 in the deployed position, extending a hammer 50 component of breaker assembly 40 through passage 16 and beneath bucket 12 . FIG. 6 is illustrated with no breaker shield for visibility.
[0042] FIG. 7 is a perspective view of bucket-breaker combination 10 of excavating machine 1 , illustrated with breaker assembly 40 in the stowed position, and covered by a breaker shield 60 . In the embodiment shown, shield 60 is attached to the interior of bucket 12 by fasteners. In this embodiment, fasteners secure shield 60 to the bottom 18 and to a rear portion 20 of the interior of bucket 12 . Also in the embodiment illustrated, shield 60 has an access door 62 to permit any necessary adjustments to breaker assembly 40 .
[0043] FIG. 8 is a side view of breaker assembly 40 , illustrated in the stowed position. Breaker assembly 40 has a frame 44 . Pivot connection 42 extends above frame 44 . A bracket 48 secures hammer 50 in place in breaker assembly 40 . Bracket 48 may comprise a pair of sides and fasteners for securing hammer 50 in breaker assembly 40 . Bracket 48 is rotatably connected at pivot connection 42 . A latch mechanism 54 is optionally affixed to frame 44 for holding breaker assembly 40 in the retracted position when desired.
[0044] FIG. 9 is a side view of shield 60 . In the embodiment illustrated, shield 60 has a flange 64 circumscribing its perimeter for attachment to bottom 18 and rear 20 of the interior of bucket 12 . A person of ordinary skill will recognize that flange 64 may be connected to the interior of bucket 12 by welding, threaded fasteners, or other known methods. As shown, shield 60 illustrates an irregular volume which closely aligns with breaker assembly 40 . This is necessary to minimize the reduction in the capacity of bucket 12 .
[0045] FIG. 10 is a perspective view of breaker assembly 40 , illustrated in the stowed position. As seen in this view, frame 44 has a frame passage 46 for the passage of hammer 50 and bracket 48 when breaker assembly 40 is rotated from the stowed position to the deployed position. Frame passage 46 is aligned with passage 16 when breaker assembly 40 is installed in bucket 12 . As also seen in FIG. 8 , pivot connection 42 extends above frame 44 . Bracket 48 secures hammer 50 in place in breaker assembly 40 . Bracket 48 is rotatably connected at pivot connection 42 . A latch mechanism 54 is optionally affixed to frame 44 for holding breaker assembly 40 in the retracted position when desired.
[0046] FIG. 11 is a bottom perspective view of breaker assembly 40 , illustrated in the stowed position. As best seen in this view, frame passage 46 is contoured to closely receive hammer 50 and bracket 48 and their collective fasteners when breaker assembly 40 is rotated from the stowed position to the deployed position.
[0047] In one embodiment, bucket-breaker assembly 40 is disclosed for use on excavating machine 1 . Bucket 12 is pivotally connected to a lower end of loader arms 4 of excavating machine 1 , and is pivotally movable on a first axis A relative to loader arms 4 . Bucket 12 has an interior and an exterior. Breaker assembly 40 is pivotally connected to bucket 12 , and is movable between a retracted position substantially internal to bucket 12 and a deployed position substantially external of bucket 12 .
[0048] In another embodiment of the bucket-breaker assembly 40 , a bucket 12 is pivotally connected to a lower end of loader arms 4 of an excavating machine 1 , and is pivotally movable along a first axis relative to the loader arms 4 . Bucket 12 has an interior and an exterior. A breaker assembly 40 is pivotally connected to bucket 12 , and movable between a retracted position and a deployed position, with the movement of the breaker assembly 40 being along a second axis that is substantially perpendicular to the first axis defining the movement of bucket 12 relative to loader arms 4 . Breaker assembly 40 is actuated from the deployed position to operate a hammer 50 .
[0049] In another embodiment of the bucket-breaker assembly 40 , a bucket 12 is pivotally connected to a lower end of loader arms 4 of an excavating machine 1 , and pivotally movable on a first axis relative to the loader arms 4 . Bucket 12 has an interior and an exterior. A passage 16 is formed on the bucket 12 , and extends between the interior and exterior of the bucket 12 . A breaker assembly 40 is pivotally connected at a breaker pivot 42 located on the interior of the bucket 12 . Breaker assembly 40 is pivotally movable between a retracted position substantially internal of bucket 12 and a deployed position through the passage 16 formed in the bucket 12 .
[0050] In another embodiment, the bucket-breaker assembly 40 further includes a latch 54 attached to the interior of the bucket 12 . Latch 54 is operable to secure the breaker assembly 40 in the retracted position inside the bucket 12 .
[0051] In another embodiment, the bucket-breaker assembly 40 further includes a shield 60 mounted to the interior of the bucket 12 . In another embodiment, shield 60 substantially covers the breaker assembly 40 when the breaker assembly is in the retracted position. In another embodiment, shield 60 substantially covers the passage 16 between the bucket interior and the bucket exterior.
[0052] In another embodiment, the bucket-breaker assembly 40 further includes a flange 64 mounted to the interior of the bucket 12 . The breaker pivot connection 42 is attached to the flange 64 . A shield 60 substantially covers the passage 16 between the bucket interior and the bucket exterior.
[0053] In another embodiment, the bucket-breaker assembly 40 further includes a portal 62 located on the shield 60 . Portal 62 is accessible from the interior of the bucket 12 to permit adjustments to the breaker assembly 40 . In another embodiment, not illustrated, the excavating machine 1 is a skid steer.
[0054] Having thus described the present invention by reference to certain of its embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered obvious and desirable by those skilled in the art based upon a review of the foregoing description of the embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | An excavating machine, representatively a skid steer, has a pair of loader arms to which an excavating bucket is mounted. A hydraulic breaker assembly is protectively mounted inside the bucket and movable to extend outward therefrom. The bucket may be operated independently of the breaker assembly for digging operations. The breaker assembly may be positioned independently of the bucket and the breaker actuated for removing refusal material. The bucket and the breaker may then be cooperatively operated to perform removal operations. The same excavating machine can be used for digging and breaking operations without the need for a second excavating machine or device dedicated to breaking the refusal material. | 4 |
BACKGROUND OF THE INVENTION
In a gas turbine engine, the compressor and turbine are supported on a shaft which extends through the engine housing. This shaft is mounted on bearings at various locations in the engine. A lubricating system supplies these bearings with the desired amounts of oil flow.
Basically, the oil is circulated within the system by a positive displacement pump which is driven by the engine shaft. The pump, therefore, is characterized by a flow rate which varies in direct proportion to engine speed.
The bearing is mounted about the shaft within a housing which is sealed at the shaft. Oil is pumped into the housing, sprayed onto the bearing and collected at the bottom of the housing to be drained into a sump. Depending on the application, drainage can be accomplished in various ways, for example, gravity, additional pumps, or bleeding high pressure air through the shaft seals. Gravity may be used only where there is sufficient room to allow for a large drainage area to insure that all of the oil flow can be drained. However, in general, drainage is impaired by the necessity of using passages having a small cross-sectional area. Therefore in many instances, problems begin to arise as the engine speed increases and the oil flow overtakes the capability of the drainage system.
Drainage may be aided by the use of the high pressure air wich is bled from the compressor stage to pressurize the main bearing seals. This high pressure air causes a flow of air into the housing through the shaft seals, thereby increasing the pressure within the housing and creating a force to improve the flow of draining oil from the housing. This method is effective at high speeds to maintain the desired drainage flow. However, its disadvantage is that under idle or shutdown conditions, the air pressure available is substantially reduced, while the pump is still operating at relatively high flow levels. This causes an undesirable build-up of oil in the bearing package resulting in greater heat absorption in the oil. Because of the low pressure differential across the seals, oil can leak through the main shaft seal and cause oil smoking of the engine.
In order to eliminate this problem, a unique oil supply system is designated to bypass excess oil flow from the pump during idle conditions and to shut off oil flow after shut-down of the engine.
SUMMARY OF THE INVENTION
A positive displacement pump circulates oil from a sump to the accessory gears and the support bearings and splines of the shaft of a gas turbine engine. The oil drops onto the bearings and settles to the bottom of the bearing housing where it is drained and returned to the sump. In order to aid drainage, high pressure air is ducted from the compressor to the area outside of the bearing housing and is allowed to leak through the shaft seal.
This high pressure air is needed to aid scavenging during the excessive oil flow at high shaft speeds. However, at idle or shutdown condition, the amount of high pressure air available is substantially reduced while oil flow remains relatively high. In order to compensate for this deficiency during idling, a bypass duct is provided to return the excess oil flow to the sump. The orifice of the duct is designed to gradually close as the pump discharge pressure increases and to dump excessive oil flow under oil pressures corresponding to the idle condition. This same excessive oil flow condition occurs after engine shutdown and to avoid the effect thereof, a check valve is inserted in the main oil duct to shut off all oil flow when the oil pressure declines below a specific value.
DESCRIPTION OF THE DRAWING
This invention is described in more detail below with reference to the attached drawing and in said drawing:
FIG. 1 is a simplified schematic flow diagram of the oil distribution system of this invention; FIG. 2 is a graph showing the oil flow characteristics of a system employing this invention;
FIG. 3 is a schematic of a typical gas turbine oil supply system employing this invention;
FIG. 4 is a sectional view of a manifold used in an oil supply system employing this invention;
FIG. 5 is a sectional view of a valve used in the oil supply system of this invention; and
FIG. 6 is a sectional view of a bearing assembly.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a simplified oil distribution system is constructed to supply oil to the support bearing assembly 1 for the shaft 2 of a gas turbine engine. The oil is circulated within the system by a positive displacement pump 3 which is driven by the gas turbine shaft 2. The pump 3 generates an oil flow (PPH) that is directly proportional to engine speed (N H ) as indicated by line 4 in the graph of FIG. 2. In FIG. 2, the engine speed N H is specified as a percentage of maximum speed. It can be observed from the graph that there is a substantial oil flow at the idle condition which is approximately 70% of full capacity.
As shown in FIG. 6, the bearing assembly 1 consists of a housing 5, ball bearings 6, and shaft seals 7 and 8. Oil enters housing 5 through duct 15 and drops through the bearing 6 to the lower portion of housing 5 where it collects and drains through duct 9. In order to aid the drainage of oil, high pressure air is bled from the compressor stages of the engine to the bearing assembly 1. This air flow passes through seal housing 7 and 8, and enters bearing housing cavity 5. This condition creates a positive pressure head that forces air and oil through the scavenge or drain duct 9, and thus, effectively maintains the oil level in the bearing housings at a desirable level.
A problem arises, however, when the engine is idling or when it is shut down because, during these periods, there is little or no high pressure air available to provide this function. Since the pump flow is still relatively high, oil tends to build up in the bearing because of the inability of the system to scavenge the oil from housing 5 at the necessary rate. This results in oil leaking through the shaft seals 7 and 8 and causes engine smoke.
In order to avoid this problem, a bypass duct 11, as best shown in FIG. 1, is constructed in the system to provide a return passage to the sump 12 for oil flow from pump 3. The duct 11 is controlled by a valve 13 which is constructed to be open at oil pressures representing idle speed or lower. The orifice of the valve is designed to allow the return of enough oil flow to compensate the poor scavenging capability of the oil distribution system at idle engine speeds and to supply full oil flow at higher speeds. The characteristic curve of the oil flow to the bearing with the bypass duct is shown by curve 16 in the graph of FIG. 2. The oil flow through the duct 11 is shown by curve 10 in the graph of FIG. 2.
In order to prevent an accumulation of oil during the gradually declining speeds which occur at engine shutdown, a check valve 14 is placed in the main supply line 15 from oil pump 3 at a position downstream of the bypass valve 13. The check valve 14 is designed to close at a pressure which indicates that the engine is at low compressor rotor speed. Oil from the pump 3, which flows during the later stages of engine deceleration, is returned through bypass duct 11 and a build-up within bearing housing 5 is avoided.
FIG. 3 illustrates a typical gas turbine engine bearing group with its associated oil distribution system. In this instance, there are six shaft bearings, 17 through 22, located at various positions along the length of the engine shaft. Bearings 18, 19 and 21, 22 are paired and each pair is mounted in a common housing. Main pump 23 provides the basic circulating flow from sump 24 through duct 25 and filter 26. Duct 25 feeds a manifold 27 which contains the check valve 28, bypass duct 29, and control valve 30. The manifold 27 is shown in FIG. 4 and feeds the housings of bearings 17 and bearing pair 21 and 22. Scavenged oil from bearings 21 and 22 is ducted directly to the accessory gear box 31 from which it is pumped by pump 32 through the cooling unit 36 to the sump 24.
The oil flow required by each bearing varies, depending on the location and the specific bearing configuration. This sometimes requires supplementary pumps, such as 33 and 34, to maintain the desired oil flow. Pump 34 drives oil from bearing 17 to the accessory gear box 31. Manifold 27 also feeds bearing 20 through supplementary pump 33, and the scavenged oil from bearing 20 is dumped directly to accessory gear box 31. Oil flow from manifold 27 is directed to the reduction gear box 35 from which it is pumped by pump 37 through cooler 36 to the sump 24.
Because of hydraulic problems which are unique to bearing pair 18 and 19, they are fed directly by pump 23 upstream of the bypass duct 29 in order to maintain maximum oil pressure.
DESCRIPTION OF VALVE AND MANIFOLD
Manifold 27 is shown in FIG. 4 and is constructed to support filter 26 and the pump units 23, 32, 33, 34 and 37. Integrally formed within the manifold is supply duct 25 which carries the main oil flow to filter 26. The oil from the filter 26 is directed through check valve 28 to bearing 17, and bearing pair 21, 22 by duct 38. A duct 39 carries oil from duct 38 to bearing pair 18, 19 and it is connected before the bypass duct 29 to insure maximum oil pressure under all conditions. Bypass duct 29 communicates with duct 38 upstream of check valve 28 and is controlled by programming valve 30 to allow oil flow back to accessory gear box 31 under idle condition. A duct 40 feeds pump element 33 to direct oil flow to bearing 20. Bypass duct 29 may be connected as shown in FIG. 3 to direct the oil flow to the accessory gear box 31 which is scavenged by pump 32. Other ducts may be integrally formed in the manifold 27 to connect the oil flow to reduction gear housing 35 which is scavenged by pump unit 37.
The control valve 30 is best shown in FIG. 5. This valve is designed to provide a variable orifice 44 for the bypass duct 29 which gradually adjusts to allow a flow of oil in duct 29 according to curve 10 of FIG. 2 in response to the pressure in the oil supply system. Specifically, the valve 13 is designed to bypass the excess oil flow present when the engine is running at idle speed and below. Above idle speeds, the valve 30 gradually closes to provide full oil flow to the engine at high speed. The operation of valve 30 must be smooth in order to avoid any large jumps in pressure which might cause problems throughout the system.
The valve 30 consists of a valve body 41 constructed with an interior chamber 42 which has an inlet 43 and an outlet 44. Valve stem 45 is slidably mounted in chamber 42 to control the size of the outlet orifice 44. The valve stem 45 is biased in the open position by spring 46. Oil pressure from inlet 43 and secondary inlet 49 exerts a force on flange 50 of valve stem 45 to overcome the bias force of spring 46. Sliding seal 47 isolates the area of high pressure oil from the spring portion of chamber 42 which is vented to atmosphere by outlet 48.
According to the above description, the following invention is claimed as novel and is desired to be secured by Letters Patent of the United States. | An oil supply system for pumping oil to the main shaft bearings seals, accessory gears and splines of a gas turbine engine is provided with a bypass duct controlled by a valve programmed to dump excessive oil flow at engine idle. The valve diverts oil flow from the bearings to prevent a build-up therein. A check valve is placed in the main supply line to the bearings and is designed to stop oil flow after engine shutdown. | 5 |
FIELD OF THE INVENTION
This invention relates to warning devices for disabled vehicles on roads and highways and more specifically relates to portable safety signs that are carried in the vehicle in case of an emergency.
BACKGROUND OF THE INVENTION
It is known that vehicles have a tendency to breakdown at completely random times, often on a major thoroughfare or highway. It is also known that accidents often occur when the difference in speed between two vehicles is greatest. Of course, the worst case of this is a disabled car on a road with other vehicles traveling at the speed limit.
Distress signs have been developed to inform passing motorists that help is needed by a stranded motorist. Examples of such devices are disclosed in U.S. Pat. No. 3,797,151 to Dexter and U.S. Pat. No. 3,623,254 to Parish, Sr. In U.S. Pat. No. 3,797,151, a magnet is utilized to mount a vertical sign to the top of a vehicle, having a legend such as "Send Help. " U.S. Pat. No. 3,623,254 discloses an interchangeable sign exhibitor, where different words may be formed to convey a message from the stranded motorist.
However, these arrangements are merely message centers and do little to help avoid collisions with stationary vehicles. The U.S. Government has set guidelines for warning devices that are intended to improve the visibility of disabled vehicles. The Department of Transportation's Standard 125 recites the scope, application and purpose of warning devices for vehicles. Standard 125 relates to devices without self-contained energy sources that are designed to be carried in motor vehicles and used to warn approaching traffic of the presence of a stopped vehicle.
Standard 125 requires a triangle with specific size and color restrictions. A known device that conforms to Standard 125 is the free standing triangle that is usually seen behind disabled trucks. According to Standard 125, the triangle must be equilateral and from 17 to 22 inches on each side. The outermost 2 to 3 inches must be composed of two colored bands; the outer one being a red reflective material to improve night visibility and the inner band being an orange fluorescent material to improve visibility. The center section of the triangle is open, permitting the passage of wind.
However, the free-standing triangles have the disadvantages of requiring heavy mounting stands or bases, to prevent blowing away in the wind, and usually collapse to a size that can only be stored in the trunk of a car, where luggage and clutter can make them inaccessible. They are also positioned on the ground, while they would be more easily spotted if they were positioned nearer to driver eye level.
Thus, is an object of the invention to provide a portable, collapsible, highway emergency sign. It is another sign that conforms to Standard 125, is easily portable, and is collapsible so it can be stored in the glove compartment of a vehicle.
It is a further object of my invention to provide a safety sign that is flexible and can generally conform to the contours of various parts of a vehicle, depending on where the sign is attached to the vehicle.
Another object of my invention is to provide a safety sign that includes means for quickly attaching/detaching the sign to a vehicle.
A further object of my invention is to protect the warning indicia on the sign when not in use.
In accordance with my invention, a foldable emergency sign comprises a number of flat slats joined by flexible hinges. The slats carry warning indicia to alert passing motorists to the presence of the disabled vehicle. The slats are also provided with magnets for quick attachment and detachment from a vehicle. A supporting harness may be provided for attaching the emergency sign to the irregularly shaped areas of a vehicle.
The foregoing and other objects and advantages of this invention will become apparent to those skilled in the art upon reading the following detailed description of a preferred embodiment in conjunction with a review of the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a detailed front view of an illustrative embodiment of my invention.
FIG. 2 is a front view of an embodiment of the invention, mounted on the rear of a vehicle.
FIG. 3 is a side view of the invention mounted to the front of a vehicle.
FIG. 4 is a top view of the invention mounted to a corner of a vehicle.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, there is depicted in FIG. 1 a portable, collapsible highway sign 10 in accordance with one specific illustrative embodiment of my invention. The highway sign comprises a plurality of rectangular slats 18 arranged in two columns interconnected by a long hinge 20 connecting the two columns of slats and short intermediate hinges 22 connecting the individual slats in each column. Positioned on the outer surface of the slats, but preferably not on the surface of the uppermost and lowermost slats 18, is the visual warning indicator, conforming to the federal standards. The warning indicator, in this embodiment of my invention, comprises an outer, generally equilateral triangle 12, and another inner, generally equilateral triangle 14, described further below.
While the safety sign in accordance with my invention may be quite large, as of the order of two feet or more high, and therefore may have a large and readily visible warning indicator, it is an aspect of my invention that the safety sign can readily be folded, first along the lengthwise hinge 20 so that the two columns are folded together, and then in accordion fashion on the intermediate hinges 22. The resultant folded sign is quite small and can readily fit into the usual glove compartment in a car.
A collapsible highway warning sign in accordance with my invention further has the advantage that it can readily and easily be manufactured. Specifically, I have found for one specific embodiment that the sign may readily be constructed from a single 20" by 24" vinyl sheet which is approximately 0.002 inches thick. The warning indicator triangle may advantageously have sides between 17" and 22" long with one bottom side positioned horizontally. The sides of the triangle 12 may be of any suitable size but are preferably between 0.75" and 1.75" wide and made of a red reflective material. A preferred reflective material is 3M SCOTCHLITE (3M Corporation, St. Paul, Minn.) Reflective Sheeting, high intensity grade. The SCOTCHLITE material has an encapsulated lens. Any highly reflective paint material that reflects incident light may be used in this element of the sign, e.g., a fresnel lens. However, to be useful in the invention, the material must be at least partially flexible, i.e., the light reflective material cannot be rigid. This material also has a pressure sensitive adhesive on the rear (non-reflective) surface. The adhesive is used to apply the material to the vinyl sheet for easy application. The dimensions of the outer triangle 12 leave approximately 4" borders at the top and bottom of the vinyl sheet. An inner triangle 14 is also mounted on the vinyl sheet within the triangle 12. The inner triangle has a width of between about 1.25" and 1.30". The triangle 14 is made of an orange fluorescent material, preferably 3M SCOTCHCAL/CONTROLTAC Marking Film, Yellow Orange No. 3483 (available from the 3M Corporation, St. Paul, Minn.). This material also has a pressure sensitive adhesive on the rear (non-reflective) surface. The center section 16 may be left bare or can preferably be provided with a silver color reflective material preferably the same material as outer triangle 12, but in silver. These different color zones can be overlapped to improve the appearance and contrast of the borders. The corners of the outer triangle 12 are chamfered. Similar triangles may also be applied to the back side of the sign 10 if desired.
To fabricate this embodiment of my invention, the vinyl sheet is then cut to produce sixteen rectangular slats 18. Preferably each slat is 3" by 10". The two triangles 12 and 14 and the center section 16 are advantageously not disposed on the top two and bottom two slats. The hinges 20 and 22 allow adjacent slats 18 to be folded on top of each other, in accordance with an aspect of my invention. The hinges 20 and 22 space the slats 18 apart by approximately 1/8" to provide gaps 24 for wind to pass through the sign 10 and to make the sign 10 easier to fold. The hinges 20 and 22 are preferably made of plastic, e.g. polyester, polyethylene, vinyl or mylar, tape. However various other types of cloth or plastic hinges that engage the side edges of adjacent slats may be employed in my invention. The center hinge 20 extends the entire length of the sign 10. Side hinges 22 are preferably positioned both near the center and near the outer edge of the slats 18 for stability.
Affixed to the top two slats 18, on the back face 10, which is on the opposite side of the triangles 12 and 14, are flexible magnetic strips 26. The strips are designed to enable the sign to be attached to a metal surface and are preferably attached with adhesive transfer tape. Similar magnet strips 28 are attached to the bottom two slats 18. The magnet strips 26 and 28 are preferably 0.125" thick by 2" wide and extend nearly the length of the respective slats 18.
A particular advantage of the sign construction of my present invention is that it may be quickly collapsed into a compact bundle that is easily stored in a small space, e.g. the glove compartment of an auto. To collapse the sign 10 for storage, it is first folded horizontally along the center hinge 20, with the triangles 12 and 14 being folded into face to face contact with one another. The sign 10 is then folded on the hinges 22 in accordion fashion. In this position, the reflective and fluorescent triangles 12 and 14 are not exposed and are protected from damage. Once in this folded configuration, the sign 10 is compact enough to be stored in a pouch in a vehicle glove compartment. The sign 10 does not require storage in a trunk or its own separate compartment.
In the unfolded position, the sign 10 can be attached to a vehicle by simply applying the top magnets 26 to any metal surface of the vehicle 100, as seen in FIGS. 2 and 3. The remainder of the sign 10 will hang down, while the bottom magnets 28 will either hang freely or preferably attach to a lower metal surface. By way of non-limiting example, the magnets 26 could be attached to the top side of a trunk lid, while the portion of the sign 10 with the triangles 12 and 14 would hang down the rear of the vehicle 100, facing oncoming traffic. The folding, set-up, attachment and detachment of the sign 10 are accomplished without tools and with minimum time and effort.
If attachment to an irregular-shaped surface, as in FIG. 4, is necessary, a support harness 36 is also provided in accordance with another aspect of my invention. Two support slats 38, preferably having the same size and shape as slats 18, have flexible support magnets 40 attached to them with transfer tape. For attachment to the support harness 36, the top two slats 18, above the magnet strips 26, are provided with support holes 42. Attached to the support slats 38 through support holes 44 are belts 48. The belts 48 are threaded through the holes 42 and the holes 44. Hook and loop fasteners, such as those sold under the trademark VELCRO (Velcro U.S.A. Inc. Manchester, N.H.) are provided along the belts 48 to secure the belts 48 onto themselves, forming a loop connecting the sign 10 and the support harness 36.
Either with or without the support harness 36, the sign 10 can be mounted at many adjustable positions on the vehicle, allowing a stranded motorist to place the sign 10 facing oncoming traffic and at nearly oncoming driver's eye level.
While the embodiment of the invention shown and described is fully capable of achieving the results desired, it is to be understood that this embodiment has been shown and described for purposes of illustration only and not for purposes of limitation. | A foldable emergency sign is provided, made up of a number of flat slats joined by flexible hinges. The slats are provided with warning indicia to alert passing motorists to the presence of a disabled vehicle. The slats are also provided with magnets for quick attachment and detachment from a vehicle. A support harness may be provided for attachment to irregularly shaped areas of a vehicle. | 1 |
The present invention relates to subsea wellhead assemblies arranged to conduct a flow of hydrocarbons from an oil and/or gas well.
BACKGROUND
Modern subsea wellhead assemblies and Xmas trees are becoming more and more advanced. The sea depths at which they are applied are increasing, involving correspondingly larger pressures. In addition, modern drilling technology results in wells that extend deeper into the ground, resulting in high temperatures of the hydrocarbons flowing out of them. The temperature of the hydrocarbons can for instance be in the area of 150-200° C. and even higher in some cases. The wellhead assemblies are also exhibiting more features than before, and comprise equipment such as electric and hydraulic connections and conductors. As an example, such connections and conductors currently used elastomeric material sealing that tolerate temperatures in the range of −18° C. to 150° C., while there is a need for equipment that tolerate temperatures up to for instance 180° C. and above. Equipment for such conditions is difficult to make, and the needed materials are significantly more expensive.
Another type of component exposed to excessive heat is seals constituting pressure barriers. Being exposed to the high pressure differences in combination with possible large variations in temperatures requires excellent material characteristics and appropriate design.
In order to account for the higher demands on the wellhead components with regards to mechanical stability, combined with the elevated temperatures of the hydrocarbons flowing through it, one has thus sought out materials with extreme characteristics. This has met the demands on the components to great extent. However, with the conditions and demands on the equipment continuously increasing, the use of better materials is not sufficient.
Another way to take into account challenges resulting from the high temperatures is to provide a more clever design of the subsea wellhead assembly, such as the design of the Xmas tree. However, there is limited available space outside the hydrocarbon-containing flow in the bore of the Xmas tree, making it difficult to overcome said challenges in this manner.
U.S. Pat. No. 6,267,172 describes a method for exchanging heat between a pipeline through which fluid is flowable and an earth heat exchanger trough which heat transfer fluid flows.
U.S. Pat. No. 4,126,406 describes downhole cooling of the electric pump motor, motor protector, and thrust bearing of a submergible pump assembly in a high temperature environment.
U.S. Pat. No. 6,032,732 describes a system for heating the well head assembly of a conventional oil well pumper.
The present invention seeks to provide equipment for a subsea wellhead assembly, such as a subsea Xmas tree, capable of complying with such extreme requirements as mentioned above. In addition, the invention seeks to reduce the demands on the components of the equipment with regards to mechanical stability combined with high temperatures, thereby omitting the use of expensive components.
SUMMARY
According to the present invention, a subsea wellhead assembly with an inner bore for conduction of produced hydrocarbon, said assembly is characterised in that it is provided with an inlet port and an outlet port at the ends of an inlet channel and outlet channel, respectively, adapted to be connected to a cooling fluid, wherein said channels extend into the assembly to a region suitable for cooling of components exposed to heating from a warm flow of said hydrocarbons.
Said inlet port and outlet port are preferably adapted to be connected to said cooling fluid by an ROV. Thus, there is provided a possibility of installing a cooling loop after the subsea wellhead assembly has been installed. If needed, such a cooling loop can be provided with a pump for flow control. In addition, if extreme cooling requirements are needed, one can also imagine installing a heat pump in order to cool the assembly with fluid significantly colder than the surrounding sea water. The inlet port and the outlet port can also advantageously be used for venting out air and to inject cooling fluid.
Herein, the term subsea wellhead assembly should be construed to involve not only the components of the wellhead itself, but also connected equipment such as a Xmas tree, tubing hanger and wellhead system.
DETAILED DESCRIPTION
Having described the main features of the subsea Xmas tree according to the present invention, a more detailed example of embodiment will now be described with reference to FIG. 1 .
FIG. 1 is a cross sectional schematic view of a vertical subsea Xmas tree 1 , arranged on the sea floor on top of a subsea well. The Xmas tree 1 has an inner bore 3 for conducting hydrocarbons from the well.
In order to prevent the Xmas tree components in the region within a wellhead 5 and above a tubing hanger 6 from being excessively heated, a cooling means 7 is arranged to the Xmas tree 1 . The cooling means 7 comprises a fluid-conducting pipe 9 . The pipe 9 has an inlet 9 a guiding cooled cooling fluid into the Xmas tree 1 and an outlet 9 b guiding heated cooling fluid out of the Xmas tree 1 . The pipe 9 also has a radiator part 9 c adapted for effective heat convection to the ambient sea water. It should be noted that a substantial part of the pipe 9 has a vertical extension. This results in a siphon effect in the cooling fluid, since the colder cooling fluid has larger density than the warmer cooling fluid. This principle is well known to a man skilled in the art. Thus, by arranging the pipe 9 with such a vertical extension, the need for a pump to provide circulation of cooling fluid is avoided.
Preferably the pipe 9 has a vertical part 9 d extending in a substantially straight manner beside the radiator part 9 c.
On an upper side of the pipe 9 there is arranged a valve 11 and an inlet port 13 for accessing the interior of the pipe 9 . The pipe channel may also be connected to a flow control valve (not shown) for the possibility of preventing flow in the pipe 9 . Such a valve can preferably be ROV 10 operated (remotely operated vehicle).
The pipe 9 interfaces with the Xmas tree 1 at an inlet port 15 a and an outlet port 15 b . From these ports 15 a , 15 b , an inlet channel 17 a and an outlet channel 17 b extend into the region 12 between Xmas tree 1 and the tubing hanger 6 , guiding cooling fluid to region 12 containing or being adjacent to components that shall be protected from excessive heating by hot flow of hydrocarbons in the bore 3 .
It should be apparent for a person skilled in the art that the above example of embodiment only describes one of a plurality of possible embodiments within the scope of the present invention, as put forth in the claims. Thus, instead of the vertical Xmas tree shown in FIG. 1 , the invention will also apply to a horizontal Xmas tree, as well as other heat-exposed parts of a subsea wellhead assembly. | Subsea wellhead assembly with an inner bore for conduction of produced hydrocarbons, equipped with a cooling means for cooling a section of the wellhead assembly exposed to heating by said hydrocarbons. | 4 |
RELATED APPLICATIONS
This application concerns subject matter related to that shown in U.S. patent application Ser. No. 09/353,943 of Mueller et al., filed Jul. 15, 1999, the disclosure of which is incorporated herein by reference, and to U.S. patent application Ser. No. 09/500154 filed Feb. 8, 2000, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to an apparatus for supporting and compliantly guiding a movable lathe carriage and, more particularly, to such an apparatus for use in the MCVD process for producing optical fiber.
BACKGROUND OF THE INVENTION
Optical fiber of the type used to carry optical signals is fabricated typically by heating and drawing a portion of an optical preform comprising a refractive core surrounded by a protective glass cladding. Presently there are several known processes for fabricating preforms. The modified chemical vapor deposition (MCVD) process, which is described in U.S. Pat. No. 4,217,027, issued in the names of J. B. MacChesney et al. on Aug. 12, 1980 and assigned to Bell Telephone Laboratories, Inc., has been found to be one of the most useful because the process enables large scale production of preforms which yield very low loss optical fiber.
During the fabrication of preforms by the MCVD process, reactant-containing gases, such as SiCl 4 and GeCl 4 are passed through a rotating substrate tube suspended between the headstock and tailstock of a lathe. A torch assembly, which heats the tube from the outside as the gases are passed therethrough, traverses the length of the tube in a number of passes, and provides the heat for the chemical reactions and deposition upon the inner wall of the tube. The torch assembly also supplies the heat for collapsing the tube to form a rod, and, in subsequent operations, for collapsing an overclad tube onto the rod, as explained in the aforementioned Mueller et al.—943 application. In the current manufacture of preforms, the torch is mounted on a carriage which is a solid structure supported and guided on the lathe or machine bed. The guidance of the carriage along a specific path is usually accomplished through the use of a typical three sided gib and way system, with the carriage having rolling or sliding elements attached and in contact with the tops, sides, and bottoms of a dual way system. Linear guide rails having various cross-sections for rolling and sliding elements and mounted to the bed may be used as an alternative. In the systems as currently used, the sliding or rolling elements on the carriage are in direct contact with the bed of the lathe or machine or with the ways. In all such systems, the movement of the carriage and the physical contact between it and the bed requires lubrication to eliminate wear and friction. An initial “stick-skip” condition must be overcome during the start of carriage motion which is a result of the friction, and the friction can also induce “jerk” in the movement of the carriage along the bed. In addition, the friction can cause or induce, over a period of time, freeplay in the system as a result of wear. Thus, where a smooth uniform velocity of the torch down the length of the tube is a necessity for uniformity of heating and deposition and, ultimately, a uniformity of product, the friction effects can, and most often do, cause a non-uniform velocity profile, and, as a consequence, non-uniformity of heating and deposition, which result in non-uniformity of product. In present day practice, friction is overcome, at least in part, through the use of lubricants which, during a production run, become a contaminant to the process and spread throughout the machine. This, in turn, necessitates frequent cleaning of the apparatus which is detrimental to the goal of substantially continuous production. Further, the lubricant does not completely eliminate the stick-slip and jerk problems which, as pointed out in the foregoing, most often lead to a nonuniform velocity profile.
The related U.S. patent application Ser. No. 09/500,154 is directed to a carriage guidance system that substantially eliminates physical contact between the carriage and lathe bed and, hence, overcomes most if not all of the aforementioned problems. The arrangement shown in that application is a hydrostatic guidance and support system for the movable carriage upon which the torch for the MCVD process is mounted. The carriage, as used on the MCVD lathe, is equipped with integral air bearing components which, in their geometry, match the lathe bed cross-section. Fluid, such as air, under pressure, is delivered to the bearings which, under pressure of the air or whatever fluid is used, in use, cause the carriage to float in spaced relationship to the lathe, thereby producing a nearly friction free support and guide for the carriage, which results in a smooth velocity profile, which, in turn, produces a drastic improvement in the quality (and quantity) of the MCVD product. The terms “fluid” and “air” will be used interchangeably hereinafter.
In greater detail, the carriage comprises a top plate to which the torch is mounted, first and second side walls depending from the top plate, and first and second inward facing guidance members in the form of flanges extending inwardly from the bottoms of the side walls. The top plate has four downwardly oriented threaded bores extending therethrough which are spaced to overlie the rails or ways of the lathe bed. Threaded studs are mounted in the bores, each stud having a partially spherical end face which fits into a hole having a spherically shaped bottom in a porous pad member thereby creating a ball joint to hold the member in place, especially while in motion. In like manner, each of the side walls has similar bores aligned with the sides of the lathe rails and in which similar studs are mounted which hold similar porous pads. Each of the flanges has a pair of bores therein for studs which also hold porous pads, beneath the ways or rails of the lathe.
On each of the side walls is mounted an air manifold having at least one air input, and six outputs having needle valves mounted therein. Thus, when pressurized air is supplied from a source to the manifold, each needle valve has a quantity of pressurized air emerging therefrom. The output of each needle valve is supplied by means of suitable tubing, to a porous pad, and each manifold supplies air to six of the pads of which there are twelve in all. Each pad, which preferably comprises porous graphite and which has a smooth porous face, has an input to which the pressurized air from the manifold is supplied. With all of the pads in place and with its pressurized air from the source being at an adjusted value of, for example, fifty-five (55) pounds per square inch, the needle valves and the threaded studs are used to fine tune the air pressure to the point where the carriage floats free of contact with the lathe bed, but properly centered on all axes. The carriage, which may be moved longitudinally by any of a number of drives, such as a worm drive, a rack and pinion drive, or a belt drive, for example, is then movable substantially without friction along the lathe bed, thereby insuring a substantially uniform velocity profile.
Inasmuch as there is no contact between the carriage and the lathe bed, lubrication and contamination of the MCVD process are eliminated.
The hydrostatic carriage arrangement of the application eliminates most of the maintenance associated with existing mechanical linear slide systems, the clogging of the lubricants in the elements, the contaminants to the process area, and velocity uniformities.
Also, because friction is substantially eliminated, the prime mover of the carriage, e.g., rack and pinion, having less of a load thereon, may be downsized in terms of the power requirements necessary to move the carriage.
Heretofore, in the prior art carriage arrangements wherein rolling or sliding elements on the carriage are in physical contact with the rails, for example, of the lathe bed, the movements of the carriage over time create wear on the moving surfaces. The wear is generally non-uniform and may progress to the point where gapping between the moving elements occurs. As the carriage traverses along the length of the bed, areas of binding or loosening may be encountered due to the wear. If a worn condition is present, the maintenance is usually directed to eliminating binding at the tightest point, which means that there will be portions of the carriage traverse that are loose. Some prior art arrangements make use of pre-loaded pivots or other spring loaded systems to maintain a uniform contact force between the moving elements. However, the number of components, which may include moving components, and their complexity impact the effectiveness of the system, and the velocity profile offer time of the carriage is directly depending upon the aforementioned factors.
The floating carriage arrangement of the aforementioned Mueller application overcomes, as pointed out, most of the problems of sticking and binding, provided the lathe bed has not been previously distorted through excess wear. Ideally, it would be a near perfect solution if the existing lathes were replaced with ones having no wear, rail bowing, or the like, but such a replacement would not be economically feasible. It would be preferable if the floating carriage arrangement could be modified to match existing rails and the like of existing lathe beds, thus making retrofit possible.
SUMMARY OF THE INVENTION
The present invention is directed to imparting to the floating carriage of the Mueller application structural elements preferably integral therewith which act as bending beam elements. The properties of the beams which extend substantially parallel to the opposite sidewall, upon which air pads are mounted allow for a spring rate to be designed into the air bearing area which can be tuned for the necessary displacement or force functions to compensate for profile irregularities. By use of such structural pre-load, gapping and binding of the carriage to the bed can be avoided and a more uniform velocity profile obtained.
In more detail, the carriage, which has two sets of air bearing pads, each set having two upper, two lower, and two side pads which are supplied with pressurized fluid, which, preferably, in the MCVD configuration, is air has first and second beams in the side walls thereof having distal ends to which the side pads are mounted. The beams may be machined into the side walls of the carriage or may be mounted thereon, and the beam properties of the geometry allow for a spring rate to be designed into the bearing area to provide adequate compensation by movement of the air bearing pads for carriage contact surface or profile irregularities in the lathe bed. Thus gapping and binding of the carriage to the bed is avoided and a more uniform velocity profile obtained. The deflection and stiffness characteristics of the beams can be matched to the bed vector loads to achieve the desired result of a floating carriage, hence a more uniform operation of the MCVD process.
These and other features and advantages of the present invention will be readily apparent from the following detailed description, read in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the floating carriage arrangement of Mueller application Ser. No. 09/500,154
FIG. 2 is a perspective view of the carriage of FIG. 1;
FIG. 3 is an exploded perspective view of elements of the carriage of FIG. 2;
FIG. 4 is a perspective view of the floating carriage of the present invention in place on the lathe bed;
FIG. 5 is a perspective view of the carriage of the invention; and
FIGS. 6 a through 6 c are a front elevation view, a side elevation view, and a plan view of the carriage of FIGS. 4 and 5 .
DETAILED DESCRIPTION
FIG. 1 is a perspective view of the carriage 11 of the aforementioned Mueller application Ser. No. 09/500,154 depicting the essential parts thereof as mounted on a lathe bed 12 . As noted hereinbefore, the present invention will be described as used on a lathe bed 12 used in the MCVD process. However, the invention may be adaptable for other configurations where jerk-free, smooth movement of an element is desired in order, primarily, to produce a uniform velocity profile, as well as to reduce wear. As can be seen in FIG. 1, lathe bed 12 comprises first and second spaced rails or tracks 13 and 14 extending along the length of the bed onto which carriage 11 is movably mounted. Carriage 11 may be driven longitudinally by any suitable or conventional means 16 , which schematically represents a rack and pinion drive, but is also intended as a representation of a worm drive or a belt drive, for example. Thus, the carriage 11 is mounted on the rails 13 and 14 and, during operation, driven back and forth along the length thereof by means of the drive 16 . Mounted on the top plate 17 of the carriage 11 is a bracket and support member 18 upon which is mounted the torch or heater member 19 used in the MCVD process. As can be seen, torch 19 has a vertical adjustment 21 for fine tuning its vertical height above the bracket 18 and hence, the lathe bed 12 . Top plate 17 has depending therefrom spaced side walls 22 and 23 at the bottom 24 of each of which is an inwardly extending flange member 26 . As thus far described, carriage 11 is similar to carriages in present use, and may be milled from a single block of suitable metal, such as aluminum, or made from separate metallic parts 17 , 22 , 23 , 26 bolted together as shown by bolts 27 , for example. In previous practice, carriage 11 has bearings or slides (not shown) which bear against the rails 13 and 14 and which, as discussed previously, are lubricated to reduce “stick-skip” and “jerk” during movement along lathe bed 12 . The carriage 11 is designed and constructed to overcome these problems and to achieve a substantially uniform velocity profile.
As shown in the Mueller application, the usual bearings or slides are replaced by a plurality of pads or air bearings 28 which are porous to the passage of air or other fluid therethrough, being made of, for example, a porous graphite material which has, as will be discussed more fully hereinafter, a smooth, flat, porous face adjacent the rails. Pads 28 are held in place by threaded studs 29 which are carried in threaded bores 30 and which provide adjustment of the pads 28 and thus separation from the surfaces of the rails or ways 13 and 14 . While the term “air” is used herein, it is to be understood that other fluids, preferably gaseous but in some cases, possibly liquid, may be used instead of air. An air manifold 31 is mounted on each of the side walls 22 and 23 . Each of the manifolds 31 has several air inputs 32 , at least one of which (not shown) is connected to a source 33 of pressurized air by an air conduit 34 . Where only a single air source 33 is used, one of the input ports 32 on the first manifold 31 can be made to function as an output which is directly connected to the input port 32 that is connected to air source 33 , to supply air through an air passage conduit 40 to an input port of the second manifold 31 , which is not shown in FIG. 1 but which is substantially identical to the one shown. Alternatively, a bore such as bore 45 in FIG. 3 which passes through carriage 11 can function as an air passage or as an internal passageway for a conduit 40 . The second manifold 31 is then connected to the air passage in the same manner as described hereinafter with respect to the air supply to pads 28 through conduits 42 at best seen in FIG. 2 . It is, of course, possible to use a second air supply 33 to supply pressurized air directly to the second manifold 31 . In FIG. 1 manifold 31 is shown with six air outlets 36 , one of which is shown connected through wall 23 to a pad 28 by means of a conduit 37 . Six conduits 37 are connected, each through a bore 38 in the side wall, to a pad 28 in the interior open volume defined by the carriage. The conduits 37 can, if desired, be routed around the ends of the carriage 11 . The first arrangement is preferred in that the conduits 37 are less likely to become snagged or otherwise interfered with by the lathe mechanisms.
In operation, when air or other fluid material under controlled pressure is applied to the manifold inlet 36 , with inlets not in use being plugged, the air is evenly divided among the six outlets 36 and passes through conduits 37 to the individual pads 28 , to emerge from their flat faces and force the pads 28 away from the surfaces of the lathe ways 13 and 14 . The studs 29 are adjusted to control the limiting spacing of the faces from the ways 13 and 14 , and, inasmuch as there are a total of twelve pads; two beneath each way; two adjacent the side of each way; and two above the top surface of each way; the carriage actually floats in contact-free relationship on each of the three axes relative to the lathe 12 . The studs 29 enable fine tuning of the structure to set the most desirable spacing of the face of the pads from the adjacent surface of the way. Once tuned, the studs are locked in place by suitable locking means, such as lock nuts 35 , one of which is shown in FIG. 3 .
FIG. 2 is a perspective view of the carriage 11 showing, in more detail, some of the elements referred to in the discussion of FIG. 1 . It can be seen that, adjacent one of the studs 29 in the sidewall, the bores 38 have couplings 39 mounted therein to which are to be attached the conduits 37 from manifold 31 . It is to be understood that all of the bores 38 , which total twelve, are to have couplings 39 affixed therein. Alternatively, bores 38 may be made large enough for conduits 37 to pass therethrough, to couple directly to pads 28 , or an interior coupler 39 to which conduits 42 are connected. Also shown are bores 41 in sidewall 23 for mounting manifold 31 . Although not shown, sidewall 22 has like bores 41 for mounting the second of the two manifold 31 . Also shown are two of the twelve pads 28 , one mounted on the interior of sidewall 22 facing inwardly and the other mounted on flange members 26 and facing upwardly. The pads 28 are connected via conduits 42 through the bores 38 and couplers 39 to the manifold 31 , not shown. The pads 28 are located such that the lower pads are beneath and closely adjacent to and face the smooth undersides of rails 12 and 14 ; the sidewall pads are closely adjacent to and face the smooth sides of rails 12 and 14 ; and the upper pads are closely adjacent to and face the smooth top surfaces of the rails 12 and 14 . Thus, when pressurized air or other fluid is applied to the porous pads 28 , a space is maintained between all of the pads and their corresponding rails and the carriage 11 floats without contacting the rails 12 and 14 . Further in order to insure stability of the carriage and prevent it from cocking relative to any of the three axes, the pads are placed relatively far apart so that they are closely adjacent the front and rear ends of the carriage. As will be seen more clearly hereinafter, the pads 28 are not fastened to their corresponding studs 29 , being free to “wobble” relative thereto. Thus, the pads 28 are, in effect, self leveling and free from any binding to the end of the stud. It can be seen that, with the arrangement just described, it is not necessary to use lubricants to insure smooth movement of the driven carriage inasmuch as there is virtually no friction between the carriage and its bearings (pads 28 ) and the lathe.
FIG. 3 is an exploded perspective view of the carriage 11 as formed in a single block, having been milled from a block of suitable metal, such as, for example, aluminum, and showing one of the manifolds 31 with needle valves 43 mounted in the outlet holes 36 .
FIG. 4 is a perspective view of the floating carriage 51 of the present invention, as formed from a single block and mounted on a lathe bed 12 having first and second rails or ways 13 and 14 . In order to avoid confusion, like paris or elements have been assigned the same reference numerals throughout the several views. As can be seen in FIG. 4, carriage 51 has a top plate 17 upon which is mounted the plate of support member 18 . On one side of plate 17 and depending therefrom is sidewall 22 on the bottom edge of which is an inwardly projecting flange member 26 (see FIG. 3 ). Air bearing pads 28 are positioned on the underside of plate 17 .
As thus far described, carriage 51 is substantially the same as carriage 11 of FIGS. 1, 2 , and 3 . In accordance with the present invention, plate 17 has a second sidewall 52 depending therefrom which comprises a central portion 53 , to which an air manifold 31 is mounted, and first and second longitudinally extending cantilevered beam members 54 and 56 , which are affixed to, preferably integrally with, central portion 53 . Beams 54 and 56 and have distal ends 57 and 58 , respectively, upon which are mounted air bearing pads 59 (only one of which is shown) and their respective mounted studs 29 in holes 60 . It will be noted that pads 59 are rectangular in shape, which illustrates the fact that any or all of the air bearing pads 28 and 59 may be shaped to produce the most desirable result. The beams 54 and 56 are preferably integral with center portion 53 and, as shown in FIG. 5, the entire carriage 51 may be milled from a single block of suitable metal, such as aluminum. Alternatively, the beams 54 and 56 may be mounted to the portion 53 . In either case, beams 54 and 56 are constructed to function as bending beam elements, their particular geometry allowing for a spring rate to be designed into the contact area of the air bearings 59 to cause bending from an increase in air pressure. The structure as thus described can be tuned for the necessary displacement of the air bearing pads to compensate for contact surface or profile irregularities. This structural preload compensates for such irregularities, and involves no moving parts (other than bending of the beams 54 and 56 ). Thus a more uniform motion profile of the carriage velocity is obtained. As the carriage 51 moves along the lathe bed, an irregularlity in the bed, such as bowing, will cause the beam to flex, due to the air pressure emanating from the air bearings 59 , rather than causing the carriage itself to move sideways, for example. Thus, the movement of carriage 51 remains smooth, without jerkiness, binding, or yawing. In the arrangement depicted in FIG. 4, only side wall 52 is shown with bending beams 54 and 56 , and the other air bearing locations and mountings are substantially the same as shown in the aforementioned Mueller patent application. It is possible, and may even be desirable in certain applications to use more than one set of bending beams. In general, it is desirable to have the bending beams, such as beams 54 and 56 , opposite a “hard” site of air bearings 28 mounted in depending wall 22 . The “hard” site functions as a reference, and follows any bends, for example, in the rail 13 . The bending beams 54 and 56 will, however, compensate for such bends and maintain the air bearings 59 at the proper gap relative to rail 14 , thereby preventing binding or contact between the rails and the carriage. In the arrangement of FIGS. 4 and 5, there are two air bearing pads 59 opposite two pads 28 in sidewall 22 , thus presenting two reference points and two flex points in a symmetrical “square” configuration. Such an arrangement works well in preventing wobbling or hunting of the carriage, and is a preferred configuration. It is possible, however, to use other configurations such as, for example, triangular. It is also possible to use bending beams in either the top or bottom of the carriage, or to use flex points opposite each other, such as, for example, in both sidewall 22 and sidewall 52 . This latter arrangement, unless the deviations in the lathe bed are known, so that the degree of flexure may be precisely set, will not necessarily function as well as the other arrangements tending to cause, among other things, hunting of the carriage as is moves along the track.
FIGS. 6 a, 6 b and 6 c illustrate the overall configuration of the carriage 51 in a front elevation view, a side elevation view, and a top plan view respectively. Carriage 51 as depicted in these figures has its top plate 17 milled out (or cast) to form reinforcing ribs 61 in order to lighten the overall carriage 51 . It can also be seen in these figures that the beam 54 and 56 are of a lesser thickness than sidewall 52 , or, more specifically, center portion 53 . Whether the carriage is cast, milled from a solid block, or pieced together, the thickness of the beams 54 and 56 are such that there is sufficient flexure to compensate for changes in spacing or gap between the air bearing pad and the lathe rails or ways. The beams can be “tuned” by varying their thickness, with the thinner beams having greater flexure. Thus, the velocity profile remains substantially uniform despite variations in the lathe ways which would otherwise cause variations in the velocity profile. Tuning of the beam essentially consists of designing the beam to have a spring rate which is matched to the lathe bed vector loads.
While the present invention has been shown and described in the context of the moving carriage in the MCVD process, it is readily adapted to other equipment or machines wherein a uniform velocity profile, or at least uniform air bearing action is required or desired, without the introduction of separate moving parts.
It is to be understood that the various features of the present invention might be incorporated into other types of apparatus and that other modifications or adaptations might occur to workers skilled in the art. All such variations and modifications are intended to be included herein as being within the scope of the invention as set forth in the claims. Further, in the claims hereinafter, the corresponding structures, materials, acts, and equivalents of all means or step-plus-function elements are intended to include any structure, material, or acts for performing the functions in combination with other elements as specifically claimed. | A hydrostatic guidance system for a moving carriage upon a lathe bed or other such machining has a plurality of fluid, preferably air bearings mounted on the carriage and a pressurized fluid manifold device for routing the pressurized fluid to the air bearings. The several air bearings are located and oriented on the carriage adjacent the rails or ways of the machine so that the carriage is made to float, contact free, over the ways for smooth, jerk free movement. At least one of the air bearings is mounted on the distal end of a bendable beam which, under pressure of the air, maintains the gap between the bearing and the way despite variations in the straightness or linearity of the way so as to maintain a uniform velocity profile. | 5 |
FIELD
[0001] The invention relates to information security field, and more particularly, to a working method of a dynamic token.
BACKGROUND
[0002] In the prior art, One-time Password (OTP) is a technology for preventing an account number from being stolen reliably and conveniently. An unpredictable random number combination is generated according to a dedicated algorithm, and each password is used for only one time. A user is required to input a one-time password besides an account number and a static password in authentication. The user can login or perform transaction normally only if the user passes the authentication of the system, so as to ensure legitimacy and uniqueness of the user identity effectively. OTP has a prominent advantage that the password used by the user each time is different and thus an illegitimate user can not personate the identity of a legitimate user. OTP authentication technology is regarded as one of the effective ways for authenticating user identity, which can effectively avoid network problems such as stealing password of account number by a hacker or Trojan, fake website, which will cause financial loss or data loss of user. At present, OTP authentication technology is widely used in fields such as e-bank, online game, telecom operator, e-administration and enterprise.
[0003] However, the inventors found that the existing password of the dynamic token has 6 or 8 digits and thus has a risk of being cracked by inversing after a stealer obtains a seed or multiple passwords, and the dynamic token is easily to be lost or stolen.
SUMMARY
[0004] In view of the defects in the prior art, a working method of a dynamic token is provided according to the present invention, for preventing the dynamic token from being stolen and lost, and avoiding seed file loss and group attack.
[0005] The technical solutions provided by the present invention are as follows.
[0006] A working method of a dynamic token includes, after the dynamic token detects that its key flag is set,
[0007] Step A, clearing the key flag, scanning keys and determining type of the key pressed down; performing Step B in a case that the key pressed down is a power key; performing Step D in a case that the key pressed down is a delete key; performing Step E in a case that the key pressed down is a key in a first numeric key group; performing Step F in a case that the key pressed down is a key in a second numeric key group; and performing Step G in a case that the key pressed down is an OK key;
[0008] Step B, checking power flag; in a case that the power flag is set, resetting the power flag and entering a dormant state; and in a case that the power flag is not set, setting the power flag and performing Step C;
[0009] Step C, checking lock flag; in a case that the lock flag is set, setting state identification to be a first predetermined value and performing Step L; and in a case that the lock flag is not set, setting the state identification to be a second predetermined value and performing Step L;
[0010] Step D, checking the power flag; in a case that the power flag is set, deleting one unit data at the end of a data cache, displaying a corresponding number, and performing Step L; and in a case that the power flag is not set, entering the dormant state;
[0011] Step E, checking the power flag; in a case that the power flag is set, storing corresponding data into the data cache, displaying a corresponding number, and performing Step L; and in a case that the power flag is not set, entering the dormant state;
[0012] Step F, checking the power flag;
[0013] in a case that the power flag is set and the state identification is a third predetermined value, determining whether time period for holding the key pressed down exceeds a predetermined time period; setting the state identification to be a fifth predetermined value and performing Step L in a case that the time period for holding the key pressed down exceeds the predetermined time period; and performing Step L directly in a case that the time period for holding the key pressed down does not exceed the predetermined time period;
[0014] in a case that the power flag is set and the state identification is not the third predetermined value, storing corresponding data into the data cache, displaying a corresponding number, and performing Step L; and
[0015] in a case that the power flag is not set, entering the dormant state;
[0016] Step G, checking the power flag;
[0017] in a case that the power flag is set, checking the state identification; performing Step H in a case that the state identification is the first predetermined value; performing Step I in a case that the state identification is the second predetermined value; performing Step J in a case that the state identification is the third predetermined value; and performing Step K in a case that the state identification is the fifth predetermined value; and
[0018] in a case that the power flag is not set, entering the dormant state;
[0019] Step H, generating an unlock verification code by computing; determining whether data in the data cache is identical to the generated unlock verification code; in a case that the data in the data cache is identical to the generated unlock verification code, resetting the lock flag, setting the state identification to be the fifth predetermined value, clearing the data in the data cache, and performing Step L; and in a case that the data in the data cache is not identical to the generated unlock verification code, clearing the data in the data cache and performing Step C;
[0020] Step I, determining whether data in the data cache is identical to a logon password currently stored in the dynamic token; in a case that the data in the data cache is identical to the logon password currently stored in the dynamic token, setting the state identification to be the third predetermined value, clearing the data in the data cache, and performing Step L; and in a case that the data in the data cache is not identical to the logon password currently stored in the dynamic token, clearing the data in the data cache, setting the lock flag, and performing Step C;
[0021] Step J, generating a dynamic password by computing, displaying content corresponding to the dynamic password and performing Step L;
[0022] Step K, determining whether data in the data cache meets a predetermined condition; in a case that the data in the data cache meets the predetermined condition, replacing the logon password currently stored in the dynamic token with the data in the data cache, clearing the data in the data cache, setting the state identification to be the third predetermined value, and performing Step L; and in a case that the data in the data cache does not meet the predetermined condition, clearing the data in the data cache and performing Step L;
[0023] Step L, determining whether the key flag is detected to be set in a predetermined time period; in a case that the key flag is detected to be set in the predetermined time period, performing Step A; and in a case that the key flag is not detected to be set in the predetermined time period, resetting the power flag and entering the dormant state.
[0024] Alternatively,
[0025] another working method of a dynamic token includes, after the dynamic token detects that its key flag is set,
[0026] Step a, clearing the key flag, scanning keys and determining type of the key pressed down; performing Step b in a case that the key pressed down is a power key; performing Step d in a case that the key pressed down is a delete key; performing Step e in a case that the key pressed down is a key in a first numeric key group; performing Step f in a case that the key pressed down is a key in a second numeric key group; and performing Step g in a case that the key pressed down is an OK key;
[0027] Step b, checking power flag; in a case that the power flag is set, resetting the power flag and entering a dormant state; and in a case that the power flag is not set, setting the power flag and performing Step c;
[0028] Step c, checking lock flag; in a case that the lock flag is set, setting the state identification to be a first predetermined value and performing Step l; and in a case that the lock flag is not set, setting the state identification to be a second predetermined value and performing Step l;
[0029] Step d, checking the power flag; in a case that the power flag is set, checking state identification, deleting one unit data at the end of a corresponding cache, displaying a corresponding number, and performing Step l; and in a case that the power flag is not set, entering the dormant state;
[0030] Step e, checking the power flag; in a case that the power flag is set, checking the state identification, storing corresponding data into a corresponding cache, displaying a corresponding number, and performing Step l; and in a case that the power flag is not set, entering the dormant state;
[0031] Step f, checking the power flag;
[0032] in a case that the power flag is set and the state identification is a third predetermined value; determining whether time period for holding the key pressed down exceeds a predetermined time period; setting the state identification to be a fifth predetermined value and performing Step l in a case that the time period for holding the key pressed down exceeds the predetermined time period; and performing Step l directly in a case that the time period for holding the key pressed down does not exceed the predetermined time period;
[0033] in a case that the power flag is set and the state identification is not the third predetermined value, checking the state identification, storing corresponding data into a corresponding cache, displaying a corresponding number, and performing Step l; and
[0034] in a case that the power flag is not set, entering the dormant state;
[0035] Step g, checking the power flag;
[0036] in a case that the power flag is set, checking the state identification; performing Step h in a case that the state identification is the first predetermined value; performing Step i in a case that the state identification is the second predetermined value; performing Step j in a case that the state identification is the third predetermined value; and performing Step k in a case that the state identification is the fifth predetermined value; and
[0037] in a case that the power flag is not set, entering the dormant state;
[0038] Step h, generating an unlock verification code by computing; determining whether data in an unlock code cache is identical to the unlock verification code generated by computing; in a case that the data in the unlock code cache is identical to the unlock verification code generated by computing, resetting the lock flag, setting the state identification to be the fifth predetermined value, clearing the data in the unlock code cache, and performing Step l; and in a case that the data in the unlock code cache is not identical to the unlock verification code generated by computing, clearing the data in the unlock code cache and performing Step c;
[0039] Step i, determining whether data in a logon password cache is identical to a logon password currently stored in the dynamic token; in a case that the data in the logon password cache is identical to the logon password currently stored in the dynamic token, setting the state identification to be the third predetermined value, clearing the data in the logon password cache, and performing Step l; and in a case that the data in the logon password cache is not identical to the logon password currently stored in the dynamic token, clearing the data in the logon password cache, setting the lock flag, and performing Step c;
[0040] Step j, generating a dynamic password by computing, displaying content corresponding to the dynamic password, and performing Step l;
[0041] Step k, determining whether data in a new logon password cache meets a predetermined condition; in a case that the data in the new logon password cache meets the predetermined condition, replacing the logon password currently stored in the dynamic token with the data in the new logon password cache, clearing the data in the new logon password cache, setting the state identification to be the third predetermined value, and performing Step 1 ; and in a case that the data in the new logon password cache does not meet the predetermined condition, clearing the data in the new logon password cache and performing Step l;
[0042] Step l, determining whether the key flag is detected to be set in a predetermined time period; in a case that the key flag is detected to be set in the predetermined time period, performing Step A; and in a case that the key flag is not detected to be set in the predetermined time period, resetting the power flag and entering the dormant state.
[0043] The present invention has advantages of effectively preventing the dynamic token from being stolen, avoiding user loss caused by the dynamic token loss and the seed loss, and reducing possibility of successful group attack.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] In order to illustrate the technical solutions according to the embodiments of the present invention or the prior art more clearly, drawings to be used in the description of the embodiments or the prior art will be described briefly hereinafter. Apparently, the drawings described hereinafter are only some embodiments of the present invention, and other drawings may be obtained by those skilled in the art according to these drawings without creative labor.
[0045] FIG. 1 is a flow chart of a working method of a dynamic token provided by a second embodiment of the present invention;
[0046] FIG. 2 is a flow chart of Step 102 to Step 117 in FIG. 1 ;
[0047] FIG. 3 is a flow chart of Step 118 to Step 126 in FIG. 1 ;
[0048] FIG. 4 is a flow chart of Step 127 to Step 138 in FIG. 1 ; and
[0049] FIG. 5 is a flow chart of Step 139 to Step 171 in FIG. 1 .
DETAILED DESCRIPTION
[0050] The technical solutions according to the embodiments of the invention will be described clearly and completely in conjunction with the drawings in the embodiments of the invention. Apparently, the described embodiments are only part but not all of embodiments of the present invention. All other embodiments obtained by those skilled in the art based on these embodiments of the present invention without creative labor should fall within the scope of protection of the present invention.
First Embodiment
[0051] In order to effectively prevent a dynamic token from being stolen and lost, and avoid seed file loss and group attack, a working method of a dynamic token is provided according to an embodiment of the present invention. In the embodiment, the dynamic token is generally in dormant state. When a key is pressed down, the dynamic token is waken up and the key flag is set. When a power key is pressed down for a time period exceeding a predetermined time period, or when there is no key entry for a predetermined time period, the dynamic token enters the dormant state again, the state identification is restored to be a default value, and the current permitted password retry time and the current state of the lock flag are stored.
[0052] In a case that the key flag is detected to be set and the initialization of the dynamic token has not been finished, the dynamic token detects whether the liquid crystal screen and the keyboard are available according to the type of the key pressed down.
[0053] In a case that the key flag is detected to be set and the initialization of the dynamic token has been finished, the dynamic token performs the following Steps S 1 to S 18 .
[0054] Step S 1 , clearing the key flag, scanning keys and determining the type of the key pressed down; performing Step S 2 in a case that the key pressed down is a power key; performing Step S 4 in a case that the key pressed down is a delete key; performing Step S 5 in a case that the key pressed down is a key in a first numeric key group; performing Step S 6 in a case that the key pressed down is a key in a second numeric key group; and performing Step S 9 in a case that the key pressed down is an OK key.
[0055] The key may be a button, a touch key, a micro switch, a photoelectric switch or an inductive switch, etc.
[0056] The power key, the delete key and the OK key may be independent keys respectively, or may be any keys in the first numeric key group respectively, or any two of them may share one key.
[0057] If the power key is a key in the first number key group, and in this step, in a case that it is determined that the key pressed down is a key in the first numeric key group, it is determined whether the key is a first predetermined key. In a case that the key is the first predetermined key, it is determined whether the time period for holding the key pressed down exceeds a predetermined time period, Step S 2 is performed in a case that the time period for holding the key pressed down exceeds the predetermined time period, and Step S 5 is performed in a case that the time period for holding the key pressed down does not exceed the predetermined time period. In a case that the key is not the first predetermined key, Step S 5 is performed.
[0058] If the delete key is a key in the first number key group, and in this step, in a case that it is determined that the key pressed down is a key in the first numeric key group, it is determined whether the key pressed down is a second predetermined key. In a case that the key pressed down is the second predetermined key, it is determined whether the time period for holding the key pressed down exceeds a predetermined time period, Step S 4 is performed in a case that the time period for holding the key pressed down exceeds the predetermined time period, and Step S 5 is performed in a case that the time period for holding the key pressed down does not exceed the predetermined time period. In a case that the key pressed down is not the second predetermined key, Step S 5 is performed.
[0059] If the OK key is a key in the first numeric key group, and in this step, in a case that it is determined that the key pressed down is a key in the first numeric key group, it is determined whether the key pressed down is a third predetermined key. In a case that the key pressed down is the third predetermined key, it is determined whether the time period for holding the key pressed down exceeds a predetermined time period, Step S 9 is performed in a case that the time period for holding the key pressed down exceeds the predetermined time period, and Step S 5 is performed in a case that the time period for holding the key pressed down does not exceed the predetermined time period. In a case that the key pressed down is not the third predetermined key, Step S 5 is performed.
[0060] If the power key and the delete key share one key, and in this step, in a case that it is determined that the key pressed down is the power key, it is determined whether the time period for holding the key pressed down exceeds a predetermined time period, Step S 2 is performed in a case that the time period for holding the key pressed down exceeds the predetermined time period, and Step S 4 is performed in a case that the time period for holding the key pressed down does not exceed the predetermined time period.
[0061] If the OK key and the power key share one key, and in this step, in a case that it is determined that the key pressed down is the OK key, it is determined whether the time period for holding the key pressed down exceeds a predetermined time period, Step S 2 is performed in a case that the time period for holding the key pressed down exceeds the predetermined time period, and Step S 9 is performed in a case that the time period for holding the key pressed down does not exceed the predetermined time period.
[0062] If the OK key and the delete key share one key, and in this step, in a case that it is determined that the key pressed down is the OK key, it is determined whether the time period for holding the key pressed down exceeds a predetermined time period, Step S 4 is performed in a case that the time period for holding the key pressed down exceeds the predetermined time period, and Step S 9 is performed in a case that the time period for holding the key pressed down does not exceed the predetermined time period.
[0063] Preferably, in the present embodiment, in order to prevent the key flag from being set due to interferences such as static electricity and bounce of a key itself, a key debounce process is performed after the token detects that the key flag is set. The key debounce process includes: after it is detected that the key flag is set, determining whether the time period for holding the key pressed down exceeds a predetermined time period; in a case that the time period for holding the key pressed down exceeds the predetermined time period, performing Step S 1 ; and in a case that the time period for holding the key pressed down does not exceed the predetermined time period, clearing the key flag, entering the dormant state, and waiting for setting of the key flag. There are multiple ways for detecting the time period for holding the key pressed down, which are not limited herein.
[0064] Preferably, in the present embodiment, the predetermined time period is 20 milliseconds.
[0065] The key debounce process may also be realized by a hardware circuit, and may specifically be realized according to the characteristic of a RS trigger.
[0066] Step S 2 , checking the power flag; in a case that the power flag is set, resetting the power flag, entering the dormant state, and performing Step S 1 when it is detected that the key flag is set again; and in a case that the power flag is not be set, setting the power flag and performing the next step.
[0067] Step S 3 , checking the lock flag; in a case that the lock flag is set, displaying information for prompting that the dynamic token is locked, setting the state identification to be a first predetermined value, displaying information for prompting entering the unlock code and performing step S 15 ; and in a case that the lock flag is not set, setting the state identification to be a second predetermined value, displaying information for prompting entering the logon password, and performing Step S 15 .
[0068] Step S 4 , checking the power flag; in a case that the power flag is set, deleting one unit data at the end of the data cache, displaying the corresponding number and performing Step S 15 , or performing Step S 15 directly if no data is in the data cache; and in a case that the power flag is not set, entering the dormant state, and performing Step S 1 when it is detected that the key flag is set again.
[0069] One unit data in the data cache represents one number; and the unit data is coded or uncoded.
[0070] The displaying the corresponding number includes: displaying numbers corresponding to all unit data in the data cache. The displayed corresponding number is plain data, or is a symbol “-”, or is the plain data for a fixed time period and then the symbol “-”. The displaying manner may be selected according to the current value of the state identification if different predetermined values of the state identification correspond to different displaying manners.
[0071] Step S 5 , checking the power flag; in a case that the power flag is set, storing corresponding data into the data cache, displaying the corresponding number, and performing Step S 15 ; and in a case that the power flag is not set, entering the dormant state, and performing Step S 1 when it is detected that the key flag is set again.
[0072] In this step,
[0073] storing corresponding data into the data cache includes: determining whether the number of the unit data in the data cache exceeds a predetermined number according to the state identification, storing a predetermined number of unit data from the first or the last unit data in a case that the number of unit data in the data cache exceeds the predetermined number; and storing all unit data in a case that the number of unit data in the data cache does not exceed the predetermined number.
[0074] Step S 6 , checking the power flag; in a case that the power flag is set, performing the next step; and in a case that the power flag is not set, entering the dormant step, and performing Step S 1 when it is detected that the key flag is set again.
[0075] Step S 7 , checking the state identification; in a case that the state identification is a third predetermined value, performing the next step; and in a case that the state identification is not the third predetermined value, storing corresponding data into the data cache, displaying the corresponding number, and performing Step S 15 .
[0076] Step S 8 , determining whether the time period for holding the key pressed down exceeds a predetermined time period; in a case that the time period for holding the key pressed down exceeds the predetermined time period, setting the state identification to be a fifth predetermined value, displaying information for prompting resetting the logon password, and performing Step S 15 ; and in a case that the time period for holding the key pressed down does not exceed the predetermined time period, performing Step S 15 directly.
[0077] Step S 9 , checking the power flag; in a case that it is detected that the power flag is set, performing the next step; and in a case that the power flag is not set, entering the dormant state, and performing Step S 1 when it is detected that the key flag is set again.
[0078] Step S 10 , checking the state identification; performing Step S 11 in a case that the state identification is the first predetermined value; performing Step S 12 in a case that the state identification is the second predetermined value; performing Step S 13 in a case that the state identification is the third predetermined value; and performing Step S 14 in a case that the state identification is the fifth predetermined value.
[0079] Step S 11 , generating an unlock verification code by computing, determining whether the data in the data cache is identical to the unlock verification code generated by computing; in a case that the data in the data cache is identical to the unlock verification code generated by computing, resetting the lock flag, setting the state identification to be the fifth predetermined value, displaying information for prompting the user to reset the logon password, clearing the data in the data cache, and performing Step S 15 ; and in a case that the data in the data cache is not identical to the unlock verification code generated by computing, clearing the data in the data cache and performing Step S 3 .
[0080] Step S 12 , determining whether the data in the data cache is identical to the logon password currently stored in the dynamic token; in a case that the data in the data cache is identical to the logon password currently stored in the dynamic token, setting the state identification to be the third predetermined value, displaying information for prompting that an information interface is entered, clearing the data in the data cache, and performing Step S 15 ; and in a case that the data in the data cache is not identical to the logon password currently stored in the dynamic token, setting the lock flag, clearing the data in the data cache, and performing Step S 3 .
[0081] Preferably, a permitted password retry time may be set in the dynamic token.
[0082] Correspondingly, in a case that the lock flag is not set, it is determined whether the data in the data cache is identical to the logon password currently stored in the dynamic token. In a case that the data in the data cache is identical to the logon password currently stored in the dynamic token, the state identification is set to be the third predetermined value, information for prompting that an information interface is entered is displayed, the permitted password retry time is set to be the initial value, the data in the data cache is cleared, and Step S 15 is performed. In a case that the data in the data cache is not identical to the logon password currently stored in the dynamic token, the data in the data cache is cleared, a result which is used as the current permitted password retry time is computed by subtracting 1 from the permitted password retry time, then it is determined whether the current permitted password retry time is 0, the lock flag is set and Step S 3 is performed in a case that the current permitted password retry time is 0, and Step S 3 is performed directly in a case that the current permitted password retry time is not 0.
[0083] Step S 13 , generating a dynamic password by computing, displaying content corresponding to the dynamic password, and performing Step S 15 .
[0084] Step S 14 , determining whether the data in the data cache meets a predetermined condition; in a case that the data in the data cache meets the predetermined condition, replacing the logon password currently stored in the dynamic token with the data in the data cache, setting the state identification to be the third predetermined value, displaying information for prompting that an information interface is entered, clearing the data in the data cache, and performing step S 15 ; and in a case that the data in the data cache does not meet the predetermined condition, clearing the data in the data cache and performing Step S 15 .
[0085] Step S 15 , determining whether the key flag is detected to be set in a predetermined time period; in a case that the key flag is detected to be set in the predetermined time period, performing Step S 1 ; and in a case that the key flag is not detected to be set in the predetermined time period, resetting the power flag, entering the dormant state, and performing Step S 1 when it is detected that the key flag is set again.
[0086] Preferably, step S 10 may further includes: performing Step S 16 in a case that the state identification is a fourth predetermined value; performing Step S 17 in a case that the state identification is a sixth predetermined value; performing Step S 18 in a case that the state identification is a seventh predetermined value.
[0087] Step S 16 , determining whether the data in the data cache is identical to the logon password currently stored in the dynamic token; in a case that the data in the data cache is identical to the logon password currently stored in the dynamic token, setting the state identification to be the fifth predetermined value, displaying information for prompting resetting the logon password, clearing the data in the data cache, and performing Step S 15 ; and in a case that the data in the data cache is not identical to the logon password currently stored in the dynamic token, clearing the data in the data cache and performing Step S 15 .
[0088] Correspondingly, Step S 8 further includes: in a case that it is determined that the time period for holding the key pressed down exceeds the predetermined time period, setting the state identification to be the fourth predetermined value, displaying information for prompting entering the current logon password, and performing Step S 15 .
[0089] Step S 17 , determining whether the data in the data cache is identical to the new logon password; in a case that the data in the data cache is identical to the new logon password, replacing the logon password currently stored in the dynamic token with the new logon password, setting the state identification to be the third predetermined value, displaying information for promoting that an information interface is entered, clearing the data in the data cache, and performing Step S 15 ; and in a case that the data in the data cache is not identical to the new logon password, setting the state identification to be the fifth predetermined value, displaying information for prompting resetting the logon password, clearing the data in the data cache, and performing Step S 15 .
[0090] Correspondingly, Step S 14 further includes: in a case that the data in the data cache meets a predetermined condition, storing the data in the data cache as a new logon password, setting the state identification to be the sixth predetermined value, displaying information for prompting confirming the reset logon password, clearing the data in the data cache, and performing Step S 15 .
[0091] Step S 18 , setting the state identification to be the third predetermined value, and performing Step S 15 .
[0092] Correspondingly, Step S 13 further includes: after generating the dynamic password by computing, setting the state identification to be a seventh predetermined value; determining whether the key flag is set before the dynamic password becomes invalid; in a case that the key flag is set before the dynamic password becomes invalid, performing Step S 1 ; and in a case that the key flag is not set before the dynamic password becomes invalid, setting the state identification to be the third predetermined value when the dynamic password becomes invalid and performing Step S 15 .
Second Embodiment
[0093] In order to effectively prevent the dynamic token from being stolen and lost, and avoid seed file loss and group attack, a method for implementing a dynamic token is provided according to an embodiment of the present invention, in which the power key and the delete key share one key, numeric keys 1 to 9 are taken as a first numeric key group, and numeric key 0 is taken as a second numeric key group. In the embodiment, the dynamic token is generally in dormant state. When a key is pressed down, the dynamic token is waken up and the key flag is set. When the time period for holding the power key pressed down exceeds a predetermined time period or when there is no key entry for a predetermined time period, the dynamic token enters the dormant state again, the state identification is restored to be a default value, and the current permitted password retry time and current state of the lock flag are stored. Referring to FIG. 1 , FIG. 2 , FIG. 3 , FIG. 4 and FIG. 5 , the dynamic token performs the following Steps 101 to 168 after it is detected that the key flag is set.
[0094] Step 101 , clearing the key flag, scanning the keyboard and determining the type of the key pressed down; performing Step 102 in a case that the key pressed down is a power key; performing Step 118 in a case that the key pressed down is any one of the numeric keys 1 to 9; performing Step 127 in a case that the key pressed down is the numeric key 0; and performing Step 139 in a case that the key pressed down is an OK key.
[0095] Step 102 , determining whether the device is initialized, performing Step 106 in a case that the device is initialized, and performing the next step in a case that the device is not initialized.
[0096] The process for initializing the device is a process for writing user information into the dynamic token.
[0097] Step 103 , the liquid crystal screen performing self-check.
[0098] Step 104 , determining whether the key flag is detected to be set in a predetermined time period, performing Step 101 in a case that the key flag is detected to be set in the predetermined time period, and performing Step 105 in a case that the key flag is not detected to be set in the predetermined time period.
[0099] Step 105 , entering the dormant state; and performing Step 101 when it is detected that the key flag is set again.
[0100] Step 106 , checking whether the power flag is set, performing Step 107 in a case that the power flag is set, and performing Step 110 in a case that the power flag is not set.
[0101] Step 107 , determining whether the time period for holding the power key pressed down exceeds a predetermined time period, performing Step 108 in a case that the time period for holding the key pressed down exceeds the predetermined time period, and performing Step 109 in a case that the time period for holding the key pressed down does not exceed the predetermined time period.
[0102] Preferably, in the second embodiment, the predetermined time period is 2 seconds.
[0103] Step 108 , resetting the power flag, entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
[0104] Step 109 , deleting one unit data at the end of the data cache, displaying the corresponding number, and performing Step 116 ; and if no data is in the data cache, skipping Step 109 and performing Step 116 directly.
[0105] One unit data in the data cache represents one number, and the one byte data is coded or uncoded. The displaying the corresponding number includes displaying numbers corresponding to all unit data in the data cache.
[0106] Step 110 , determining whether the time period for holding the power key pressed down exceeds a predetermined time period, performing Step 111 in a case that the time period for holding the power key pressed down exceeds the predetermined time period, and performing Step 112 in a case that the time period for holding the power key pressed down does not exceed the predetermined time period.
[0107] Step 111 , entering the dormant state; and performing Step 101 when it is detected that the key flag is set again.
[0108] Step 112 , setting the power flag.
[0109] Step 113 , detecting whether the lock flag is set, performing Step 114 in a case that the lock flag is set, and performing Step 115 in a case that the lock flag is not set.
[0110] Step 114 , setting the state identification to be a first predetermined value, displaying an unlock code entering interface, and performing Step 116 .
[0111] Step 115 , setting the state identification to be a second predetermined value, and displaying a logon password entering interface.
[0112] Step 116 , determining whether the key flag is detected to be set in a predetermined time period, performing Step 101 in a case that the key flag is detected to be set in the predetermined time period, and performing Step 117 in a case that the key flag is not detected to be set in the predetermined time period.
[0113] Step 117 , resetting the power flag, entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
[0114] Step 118 , determining whether the device is initialized, performing Step 122 in a case that the device is initialized, and performing Step 119 in a case that the device is not initialized.
[0115] Step 119 , displaying the corresponding number.
[0116] Step 120 , determining whether the key flag is detected to be set in a predetermined time period, performing Step 101 in a case that the key flag is detected to be set in the predetermined time period, and performing Step 121 in a case that the key flag is not detected to be set in the predetermined time period.
[0117] Step 121 , entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
[0118] Step 122 , detecting whether the power flag is set, performing Step 124 in a case that the power flag is set, and performing Step 123 in a case that the power flag is not set.
[0119] Step 123 , entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
[0120] Step 124 , storing the corresponding data into the data cache and displaying the corresponding number.
[0121] Preferably, in the present embodiment, in a case that the state identification is the second predetermined value or a fourth predetermined value or a fifth predetermined value or a sixth predetermined value, it is determined whether the number of the unit data in the data cache exceeds 6, the first or the last 6 unit data are stored in a case that the number of the unit data in the data cache exceeds 6, and all unit data are stored in a case that the number of the unit data in the data cache does not exceed 6. In a case that the state identification is the first predetermined value, it is determine whether the number of the unit data in the data cache exceeds 8, the first or the last 8 unit data are stored in a case that the number of the unit data in the data cache exceeds 8, and all unit data are stored in a case that the number of the unit data in the data cache does not exceeds 8.
[0122] The displaying the corresponding number includes displaying numbers corresponding to all unit data in the data cache.
[0123] The displayed corresponding number may be plain data, or may be a symbol such as “-” or “*”, or may be plain data for some time period and then a symbol such as “-” or “*”. If different state identifications correspond to different displaying manners, the displaying manner may be selected according to the state identification.
[0124] Step 125 , determining whether the key flag is detected to be set in a predetermined time period, performing Step 101 in a case that the key flag is detected to be set in the predetermined time period, and performing Step 126 in a case that the key flag is not detected to be set in the predetermined time period.
[0125] Step 126 , resetting the power flag, entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
[0126] Step 127 , determining whether the device is initialized, performing Step 131 in a case that the device is initialized, and performing Step 128 in a case that the device is not initialized.
[0127] Step 128 , displaying the number 0.
[0128] Step 129 , determining whether the key flag is detected to be set in a predetermined time period, performing Step 101 in a case that the key flag is detected to be set in the predetermined time period, and performing Step 130 in a case that the key flag is not detected to be set in the predetermined time period.
[0129] Step 130 , entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
[0130] Step 131 , checking whether the power flag is set, performing Step 133 in a case that the power flag is set, and performing Step 132 in a case that the power flag is not set.
[0131] Step 132 , entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
[0132] Step 133 , checking the state identification; performing Step 135 in a case that the state identification is a third predetermined value, and performing Step 134 in a case that the state identification is not the third predetermined value.
[0133] Step 134 , storing the corresponding data into the data cache, displaying the corresponding number, and performing Step 137 .
[0134] The implementation of Step 134 is identical to that of Step 124 , and the detailed description is omitted therein.
[0135] Step 135 , determining whether the time period for holding the numeric key 0 pressed down exceeds a predetermined time period, performing Step 136 in a case that the time period for holding the numeric key 0 pressed down exceeds the predetermined time period, and performing Step 137 in a case that the time period for holding the numeric key 0 pressed down does not exceed the predetermined time period.
[0136] Step 136 , setting the state identification to be the fourth predetermined value, displaying a logon password changing interface, and performing Step 137 .
[0137] Step 137 , determining whether the key flag is detected to be set in a predetermined time period, performing Step 101 in a case that the key flag is detected to be set in the predetermined time period, and performing Step 138 in a case that the key flag is not detected to be set in the predetermined time period.
[0138] Step 138 , resetting the power flag, entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
[0139] Step 139 , determining whether the device is initialized, performing Step 143 in a case that the device is initialized, and performing Step 140 in a case that the device is not initialized.
[0140] Step 140 , displaying predetermined information.
[0141] In the present embodiment, the predetermined information is “success”.
[0142] Step 141 , determining whether the key flag is detected to be set in a predetermined time period, performing Step 101 in a case that the key flag is detected to be set in the predetermined time period, and performing Step 142 in a case that the key flag is not detected to be set in the predetermined time period.
[0143] Step 142 , entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
[0144] Step 143 , checking whether the power flag is set, performing Step 145 in a case that the power flag is set, and performing Step 144 in a case that the power flag is not set.
[0145] Step 144 , entering the dormant state and performing Step 101 when it is detected that the key flag is set again.
[0146] Step 145 , checking the state identification, performing Step 146 in a case that the state identification is the third predetermined value; performing Step 149 in a case that the state identification is the second predetermined value; performing Step 151 in a case that the state identification is the first predetermined value; performing Step 157 in a case that the state identification is the fourth predetermined value; performing Step 160 in a case that the state identification is the fifth predetermined value; performing Step 163 in a case that the state identification is the sixth predetermined value; and performing Step 166 in a case that the state identification is a seventh predetermined value.
[0147] Step 146 , generating a dynamic password by computing, setting the state identification to be the seventh predetermined value and displaying content corresponding to the dynamic password.
[0148] In the present embodiment, the dynamic token generates a dynamic password with 6 digits by computing. The dynamic password may be generated according to a time factor (or an event factor) and a static factor pre-stored in the dynamic token, or according to a time factor (or an event factor), data in the data cache and a static factor pre-stored in the dynamic token, which is not limited herein.
[0149] Preferably, in the present embodiment, the displaying the corresponding data includes displaying the first four digits of the dynamic password and symbols “-” for the last two digits.
[0150] Further, a time bar may be displayed for representing the remained valid time of the current dynamic password.
[0151] Step 147 , determining whether the key flag is detected to be set when the dynamic password is valid, performing Step 101 in a case that the key flag is detected to be set when the dynamic password is valid, and performing Step 148 when the dynamic password is invalid in a case that the key flag is not detected to be set when the dynamic password is valid.
[0152] Step 148 , setting the state identification to be the third predetermined value, displaying an information interface, and performing Step 167 .
[0153] Step 149 , generating an unlock verification code by computing, and determining whether the data in the data cache is identical to the unlock verification code, performing Step 150 in a case that the data in the data cache is identical to the unlock verification code, and performing Step 155 in a case that the data in the data cache is not identical to the unlock verification code.
[0154] The dynamic token generates three unlock verification codes each of which has 8 digits by using a predetermined algorithm according to a static factor and a time factor (or an event factor), or according to a static factor, a time factor (or an event factor) and data in the data cache. The three unlock verification codes respectively correspond to the time factor previous to the current time factor, the current time factor and the time factor next to the current time factor, or respectively correspond to the current event factor, the event factor next to the current event factor and the event factor next to the next event factor of the current event factor.
[0155] Further, the determining whether the corresponding number in the data cache is identical to the unlock verification code includes determining whether the corresponding number in the data cache is identical to any one of the three unlock verification codes generated by the dynamic token.
[0156] Step 150 , clearing the data in the data cache, resetting the lock flag, setting the state identification to be the fifth predetermined value, displaying a new logon password setting interface, and performing Step 167 .
[0157] Step 151 , determining whether the data in the data cache is identical to the logon password stored in the dynamic token, performing Step 156 in a case that the data in the data cache is identical to the logon password stored in the dynamic token, and performing Step 152 in a case that the data in the data cache is not identical to the logon password stored in the dynamic token.
[0158] Step 152 , clearing the data in the data cache, and computing a result, which is used as the permitted password retry time, by subtracting 1 from the current password retry time.
[0159] In the present embodiment, if it is the first time that Step 152 is performed, the initial value of the current password retry time is 6; otherwise, the current password retry time is the permitted password retry time obtained by performing Step 152 last time.
[0160] Step 153 , determining whether the permitted password retry time is 0; in a case that the permitted password retry time is 0, setting the lock flag and performing Step 154 ; and in a case that the permitted password retry time is not 0, performing Step 154 directly.
[0161] Step 154 , prompting that the logon password is error, prompting the permitted password retry time, and performing Step 155 .
[0162] Step 155 , clearing the data in the data cache and performing Step 113 .
[0163] Step 156 , clearing the data in the data cache, setting the state identification to be the third predetermined value, displaying an information interface, and performing Step 167 .
[0164] Step 157 , determining whether the data in the data cache is identical to the logon password stored in the dynamic token, performing Step 158 in a case that the data in the data cache is identical to the logon password stored in the dynamic token, and performing Step 159 in a case that the data in the data cache is not identical to the logon password stored in the dynamic token.
[0165] Step 158 , clearing the data in the data cache, setting the state identification to be the fifth predetermined value, displaying a new logon password setting interface, and performing Step 167 .
[0166] Step 159 , clearing the data in the data cache, prompting that the logon password is error, and performing Step 167 .
[0167] Step 160 , determining whether the data in the data cache meets a predetermined condition, performing Step 161 in a case that the data in the data cache meets the predetermined condition, and performing Step 162 in a case that the data in the data cache does not meet the predetermined condition.
[0168] Preferably, in the present embodiment, the data in the data cache meets the predetermined condition is that the data in the data cache corresponds to 6 digits which are numbers from 0 to 9.
[0169] Step 161 , clearing the data in the data cache, storing the data entered by the user as P1, setting the state identification to be the sixth predetermined value, displaying a new logon password confirmation interface, and performing Step 167 .
[0170] Step 162 , clearing the data in the data cache, prompting failure of the logon password changing, and performing Step 167 .
[0171] Step 163 , determining whether the data in the data cache is identical to P1, performing Step 165 in a case that the data in the data cache is identical to P1, and performing Step 164 in a case that the data in the data cache is not identical to P1.
[0172] Step 164 , clearing the data in the data cache, prompting failure of logon password changing, setting the state identification to be the fifth predetermined value, displaying a new logon password setting interface, and performing Step 167 .
[0173] Step 165 , clearing the data in the data cache, replacing the logon password stored in the dynamic token with P1, setting the state identification to be the third predetermined value, displaying an information interface, and performing Step 167 .
[0174] Step 166 , setting the state identification to be the third predetermined value and displaying an information interface.
[0175] Step 167 , determining whether the key flag is detected to be set in a predetermined time period, performing Step 101 in a case that the key flag is detected to be set in the predetermined time period, and performing Step 168 in a case that the key flag is not detected to be set in the predetermined time period.
[0176] Step 168 , resetting the power flag, entering the dormant state, and performing Step 101 when it is detected that the key flag is set again.
Third Embodiment
[0177] In order to effectively prevent a dynamic token from being stolen and lost, and avoid seed file loss and group attack, another working method of a dynamic token is provided according to an embodiment of the present invention. In the embodiment, the dynamic token is generally in a dormant state. When a key is pressed down, the dynamic token is waken up and the key flag is set. When a power key is pressed down for a time period exceeding a predetermined time period, or when there is no key entry for a predetermined time period, the dynamic token enters the dormant state again, the state identification is restored to be a default value, and the current permitted password retry time and the current state of the lock flag are stored.
[0178] In a case that the key flag is detected to be set and the initialization of the dynamic token has not been finished, the dynamic token detects whether the liquid crystal screen and the keyboard are available according to the type of the key pressed down.
[0179] In a case that the key flag is detected to be set and the initialization of the dynamic token has been finished, the dynamic token performs the following Steps 201 to 215 .
[0180] Step 201 , clearing the key flag, scanning keys and determine the type of the key pressed down; performing Step 202 in a case that the key pressed down is a power key; performing Step 203 in a case that the key pressed down is a delete key; performing Step 204 in a case that the key pressed down is a numeric key; and performing Step 206 in a case that the key pressed down is an OK key.
[0181] Preferably, in the third embodiment, in order to prevent the key flag from being set due to interferences such as static electricity and bounce of the key itself, a key debounce process is performed after the token detects that the key flag is set. The key debounce process includes: after it is detected that the key flag is set, determining whether the time period for holding the key pressed down exceeds a predetermined time period; in a case that the time period for holding the key pressed down exceeds the predetermined time period, performing Step S 1 ; and in a case that the time period for holding the key pressed down does not exceed the predetermined time period, clearing the key flag, entering the dormant state, and waiting for setting of the key flag. There are multiple ways for detecting the time period for holding the key pressed down, which are not limited herein.
[0182] Preferably, in the present embodiment, the predetermined time period is 20 milliseconds.
[0183] The key debounce process may also be realized by a hardware circuit, and may specifically be realized according to the characteristic of a RS trigger.
[0184] Step 202 , checking the power flag;
[0185] in a case that the power flag is set, resetting the power flag, entering the dormant state, and performing Step 201 when it is detected that the key flag is set again; and
[0186] in a case that the power flag is not set, setting the power flag and performing Step 203 .
[0187] Step 203 , checking whether the lock flag is set; in a case that the lock flag is set, displaying information for promoting that the dynamic token has been locked, setting the state identification to be a first predetermined value, displaying information for promoting entering the unlock code, and performing Step 212 ; and in a case that the lock flag is not set, setting the state identification to be a second predetermined value, displaying information for promoting entering the logon password, and performing Step 212 .
[0188] Step 204 , checking the power flag;
[0189] in a case that the power flag is set, checking the state identification,
deleting one corresponding unit data at the end of the corresponding cache, displaying the corresponding number, and performing Step 212 , and performing Step 212 directly if no data is in the corresponding cache; and
[0192] in a case that the power flag is not set, entering the dormant state, and performing Step 201 when it is detected that the key flag is set again.
[0193] Specifically, the checking the state identification and deleting one unit data at the end of the corresponding cache includes:
[0194] checking the state identification; in a case that the state identification is the first predetermined value, deleting a unit data at the end of the unlock code cache; in a case the state identification is the second predetermined value or a fourth predetermined value, deleting a unit data at the end of the logon password cache; in a case that the state identification is a fifth predetermined value, deleting a unit data at the end of the new logon password cache; in a case that the state identification is a sixth predetermined value, deleting a unit data at the end of the new logon password confirmation cache; and in a case that the state identification is other value, performing no operation.
[0195] One unit data in the data cache represents a number; and the one unit data is coded or uncoded.
[0196] The displaying the corresponding number includes: displaying numbers corresponding to all unit data in the data cache. The displayed corresponding number is plain data, or is a symbol “-”, or is the plain data for a fixed time period and then the symbol “-”. If different predetermined values of the state identification correspond to different displaying manners, the displaying manner may be selected according to the current value of the state identification.
[0197] Step 205 , checking the power flag; in a case that the power flag is set, checking the state identification, storing corresponding data into the corresponding cache according to the value of the key, and performing Step 212 ; and in a case that the power flag is not set, entering the dormant state, and performing Step 201 when it is detected that the key flag is set again.
[0198] Specifically, the checking the state identification and storing corresponding data into the corresponding cache according to the value of the key includes: checking the state identification; in a case that the state identification is the first predetermined value, storing the corresponding data into the unlock code cache; in a case that the state identification is the second predetermined value or the fourth predetermined value, storing the corresponding data into the logon password cache; in a case that the state identification is the fifth predetermined value, storing the corresponding data into the new logon password cache; in a case that the state identification is the sixth predetermined value, storing the corresponding data into the new logon password confirmation cache; and in a case that the state identification is other value, performing no operation.
[0199] The storing corresponding data into the corresponding data cache includes: determining whether the number of the unit data in the corresponding cache exceeds a predetermined number according to the state identification; storing a predetermined number of unit data from the first or the last unit data in a case that the number of the unit data in the corresponding cache exceeds the predetermined number; and storing all unit data in a case that the number of the unit data in the corresponding cache does not exceed the predetermined number.
[0200] Step 206 , checking the power flag;
[0201] in a case that the power flag is set, checking the state identification,
in a case that the state identification is a third predetermined value, determining whether the time period for holding the key pressed down exceeds a predetermined time period;
in a case that the time period for holding the key pressed down exceeds the predetermined time period, setting the state identification to be the fifth predetermined value, displaying information for promoting resetting the logon password, and performing Step 212 ; and in a case that the time period for holding the key pressed down does not exceed the predetermined time period, performing Step 212 directly; and
in a case that the state identification is not the third predetermined value, storing the corresponding data into the corresponding cache, displaying the corresponding number, and performing Step 212 ; and
[0206] in a case that the power flag is not set, entering the dormant state, and performing Step 211 when it is detected that the key flag is set again.
[0207] The storing the corresponding data into the corresponding cache in a case that the state identification is not the third predetermined value includes: in a case that the state identification is the first predetermined value, storing the corresponding data into the unlock code cache; in a case that the state identification is the second predetermined value or the fourth predetermined value, storing the corresponding data into the logon password cache; in a case that the state identification is the fifth predetermined value, storing the corresponding data into the new logon password cache; in a case that the state identification is the sixth predetermined value, storing the corresponding data into the new logon password confirmation cache; and in a case that the state identification is other value, performing no operation.
[0208] Step 207 , checking the power flag; in a case that the power flag is set, checking the state identification, performing Step 208 in a case that the state identification is the first predetermined value, performing Step 209 in a case that the state identification is the second predetermined value, performing Step 210 in a case that the state identification is the third predetermined value, and performing Step 211 in a case that the state identification is the fifth predetermined value; and in a case that the power flag is not set, entering the dormant state, and performing Step 201 when it is detected that the key flag is set again.
[0209] Step 208 , generating an unlock verification code by computing; determine whether the data in the unlock code cache is identical to the generated unlock verification code; in a case that the data in the unlock code cache is identical to the generated unlock verification code, resetting the lock flag, setting the state identification to be the fifth predetermined value, displaying information for prompting the user to reset the logon password, clearing the data in the unlock code cache, and performing Step 212 ; and in a case that the data in the unlock code cache is not identical to the generated unlock verification code, clearing the data in the unlock code cache, and performing Step 203 .
[0210] Specifically, the method for generating the unlock verification code by computing is the same as the method for generating the unlock verification code by computing in the second embodiment, and the detailed description is omitted herein.
[0211] Step 209 , determining whether the data in the logon password cache is identical to the logon password currently stored in the dynamic token; in a case that the data in the logon password cache is identical to the logon password currently stored in the dynamic token, setting the state identification to be the third predetermined value, displaying information for prompting that an information interface is entered, clearing the data in the logon password cache, and performing Step 212 ; and in a case that the data in the logon password cache is not identical to the logon password currently stored in the dynamic token, setting the lock flag, clearing the data in the logon password cache, and performing Step 203 .
[0212] Preferably, a permitted password retry time may be set in the dynamic token.
[0213] Correspondingly, in a case that the lock flag is not set, it is determined whether the data in the logon password cache is identical to the logon password currently stored in the dynamic token,
[0214] in a case that the data in the logon password cache is identical to the logon password currently stored in the dynamic token, the state identification is set to be the third predetermined value, information for promoting that an information interface is entered is displayed, the permitted password retry time is set to be the initial value, the data in the logon password cache is cleared, and Step 212 is performed; and
[0215] in a case that the data in the logon password cache is not identical to the logon password currently stored by the dynamic token, the data in the logon password cache is cleared, a result, which is used as the current permitted password retry time, is computed by subtracting 1 from the permitted password retry time, and it is determined whether the current permitted password retry time is 0, the lock flag is set and Step 203 is performed in a case that the current permitted password retry time is 0, and Step 203 is performed directly in a case that the current permitted password retry time is not 0.
[0216] Step 210 , generating a dynamic password by computing, displaying content corresponding to the dynamic password, and performing Step 212 .
[0217] Specifically, the method for generating the dynamic password by computing is the same as the method for generating the dynamic password by computing in the second embodiment, and the detailed description is omitted herein.
[0218] Step 211 , determining whether the data in the new logon password cache meets a predetermined condition; in a case that the data in the new logon password cache meets the predetermined condition, replacing the logon password currently stored in the token with the data in the new logon password cache, setting the state identification to be the third predetermined value, displaying information for promoting that an information interface is entered, clearing the data in the new logon password cache, and performing Step 212 ; and in a case that the data in the new logon password cache does not meet the predetermined condition, clearing the data in the new logon password cache, and performing Step 212 .
[0219] Step 212 , determining whether the key flag is detected to be set in a predetermined time period; in a case that the key flag is detected to be set in the predetermined time period, performing Step 201 ; and in a case that the key flag is not detected to be set in the predetermined time period, resetting the power flag, entering the dormant state, and performing Step 201 when it is detected that the key flag is set again.
[0220] Preferably, Step 207 further includes: in a case that the state identification is the fourth predetermined value, performing Step 213 ; in a case that the state identification is the sixth predetermined value, performing Step 214 ; and in a case that the state identification is a seventh predetermined value, performing Step 215 .
[0221] Step 213 , determining whether the data in the logon password cache is identical to the logon password currently stored in the dynamic token; in a case that the data in the logon password cache is identical to the logon password currently stored in the dynamic token, setting the state identification to be the fifth predetermined value, displaying information for promoting resetting the logon password, clearing the data in the logon password cache, and performing Step 212 ; and in a case that the data in the logon password cache is not identical to the logon password currently stored in the dynamic token, clearing the data in the logon password cache, and performing Step 212 .
[0222] Correspondingly, Step 206 further includes: in a case that it is determined the time period for holding the key pressed down exceeds the predetermined time period, setting the state identification to be the fourth predetermined value, displaying information for promoting entering the current logon password, and performing Step 212 .
[0223] Step 214 , determining whether the data in the logon password confirmation cache is identical to a new logon password; in a case that the data in the logon password confirmation cache is identical to the new logon password, replacing the logon password currently stored in the dynamic token with the new logon password, setting the state identification to be the third predetermined value, displaying information for promoting that an information interface is entered, clearing the data in the logon password confirmation cache, and performing Step 212 ; and in a case that the data in the logon password confirmation cache is not identical to the new logon password, setting the state identification to be the fifth predetermined value, displaying information for prompting resetting the logon password, clearing the data in the logon password confirmation cache, and performing Step 212 .
[0224] Correspondingly, in Step 211 , in a case that the data in the new logon password cache meets the predetermined condition, the data in the new logon password cache is stored as the new logon password, the state identification is set to be the sixth predetermined value, the information for prompting confirming the reset logon password is displayed, the data in the new logon password cache is cleared, and Step 212 is performed.
[0225] Step 215 , setting the state identification to be the third predetermined value and performing Step 212 .
[0226] Correspondingly, Step 210 further includes: after generating the dynamic password by computing, setting the state identification to be the seventh predetermined value and determining whether the key flag is set before the dynamic password becomes invalid; in a case that the key flag is set before the dynamic password becomes invalid, performing Step 201 ; and in a case that the key flag is not set before the dynamic password becomes invalid, setting the state identification to be the third predetermined value when the dynamic password becomes invalid, and performing Step 212 .
[0227] Specifically, in the present embodiment, the unlock code cache and the logon password cache share a same storing region. In addition, there are other ways for cache sharing, for example, the unlock code cache and the new logon password cache may share a same storing region.
[0228] The above are only embodiments of the present invention. Any modification and equivalent substitute made by those skilled in the art within the technical scope of the present disclosure without any creative labor should fall into the protection scope of the present invention. The protection scope of the present invention should follow the protection scope of the claims. | Disclosed is a one-time password operating method, comprising: when a one-time password detects a valid key, judging the type of a pressed key, if the pressed key is a power-on key, detecting whether a current power-on logo is set, if yes, resetting same, otherwise, setting same and inspecting whether a locking logo is set, if yes, entering an unlocking code interface, otherwise entering an information interface; if the pressed key is a delete key, deleting data at the tail end of a data cache area; if the pressed key is a number key and the one-time password is not in the information interface, storing corresponding data in the data cache area; if the one-time password is in the information interface, judging whether the time for the key being pressed down goes beyond a preset time period, if yes, entering a power-on password modifying interface, otherwise storing corresponding data in the data cache area; if the pressed key is an Enter key and the one-time password is not in the information interface, judging whether the data in the data cache area are correct or meet requirements, if the one-time password is in the information interface, generating a dynamic password and displaying corresponding contents. | 7 |
DESCRIPTION
The invention relates to an arrangement for damping linear movements for use on a safety valve.
A damping arrangement of this type is described in FR-A No. 2 389 047.
In the latter, two cup-shaped damping parts, which together define a working gap filled with a viscous medium, have a fixed, predetermined axial position.
If one were to use a damping arrangement of this type on a safety valve, then the damping would not be satisfactory, since the damping comes into action reliably on the one hand already at very small opening displacements of the closure part, irrespective of manufacturing tolerances, which result for example from the machining of the sealing surfaces. Also, in safety valves of this type, the force acting on the valve spindle also varies very considerably depending on the opening displacement and the known damping arrangement thus cannot damp oscillations, which occur in the immediate vicinity of the closing position, as well as other oscillations which are set up around a partly open position.
The present invention therefore intends to develop an arrangement for damping linear movements so that the damping characteristics can be adjusted precisely in a simple manner.
This object is achieved according to the invention by a damping arrangement C.
Advantageous developments of the invention are described in the Sub-claims.
In another damping arrangement, the value of the displacement-independent component of the damping can be adjusted in a very simple manner. One can thus adjust the damping properties of the safety valve easily at the installation point taking into consideration the lengths of the pipe sections connected to the safety valve at the inlet side and the outlet side.
In a damping arrangement according to another embodiment, a small displacement-dependent component of the damping can be adjusted, this component being progressive or degressive according to the pitch of the support-screw coupling.
The development of the invention according to another embodiment is an advantage with regard to the lowest possible abrasive nature of the viscous medium.
The invention will be described in detail hereafter by means of embodiments, referring to the drawings, in which:
FIG. 1 is an axial section through a damping arrangement for a valve spindle operating with a viscous medium; and
FIG. 2 is a similar sectional view to FIG. 1, in which a modified damping arrangement is illustrated.
FIG. 1 shows the upper end of a valve spindle 10, which is provided with a threaded section 12. The valve spindle is guided on a valve housing by way of sliding packings (which are not shown in detail) and at its lower end not shown in the drawing supports a closure member, which co-operates with a valve seat likewise not shown.
Of the valve housing, only an upper end section of the housing 14 is shown, which receives a damping arrangement acting on the valve spindle 10 and designated generally by the reference numeral 16.
Belonging to the damping arrangement 16 is a lower damping part 18, which comprises a transverse base 20 and two working walls 22, 24 coaxial with respect to the axis of the valve spindle 10.
The base 20 is clamped between two threaded rings 26, 28, whereof the external threads engage in an internal thread 30 of the end section of the housing 14.
Engaging between the working walls 22, 24 in the manner of a comb is a further working wall 32, which is supported by a hub section 34. The components 32 and 34 together form an upper damping part 36.
The damping part 36 is mounted by way of an axial/radial bearing 38 on the end section of the housing 14.
The hub section 34 is provided with an internal thread 40, which co-operates with the threaded section 12 of the valve spindle 10.
The annular space defined by the working walls 22, 24 is filled with a highly viscous silicone grease 42. The latter contains graphite as a filler component or as the exclusive filler. The level of the silicone grease 42 extends above the lower edge of the suspended working wall 32 of the upper damping part 36.
The inner surface of the working wall 24 and the outer surface of the working wall 32 as well as the inner surface of the working wall 32 and the outer surface of the working wall 22 form two pairs of working surfaces, between which the annular working gaps 44, 46 are located. A thin layer of silicone grease 42 is located in these working gaps. The thickness of the working gaps is illustrated in an exaggerated manner in the drawing; in practice the thickness of the gap amounts to approximately 0.1 to approximately 1 mm.
If the valve spindle 10 is moved in a linear manner, for example due to pressure surges acting on the closure member in the pipe to be protected, then the linear movement of the valve spindle 10 is converted by a movement conversion transmission, which is formed by the co-operating threads 12 and 40 as well as the axial/radial bearing 38, into a pure rotary movement. This rotary movement leads to shearing of the silicone grease 42 located in the working gaps 44, 46, and due to the inner friction of this highly viscous medium, the movement of the valve spindle 10 is damped.
It can be seen that irrespective of the distance covered by the valve spindle 10, one has exactly the same working gap geometry, so that the damping of the movement takes place independently of the displacement.
The embodiment illustrated in FIG. 2 corresponds largely to that according to FIG. 1, so that corresponding components have again been given the same reference numerals and are not described again in detail hereafter.
The upper damping part 36 is now not mounted by way of an axial/radial bearing, but by way of an external thread 48 on the hub section 34 and a matching thread 50 integral with the housing, on the end section of the housing 14. Compared with the treaded section 12 of the valve spindle 10, the threads 48 and 50 have a small pitch so that for a given axial movement of the valve spindle 10, one obtains only a small axial adjustment of the upper damping part 36, thus also a small variation of the penetration depth of the working wall 32 into the silicone grease 42. In this case, this variation of the penetration depth may be positive or negative, according to whether the pair of threads 48, 50 has the same direction of rotation as the pair of threads 12, 40 or the opposite direction of the rotation. The extent of the displacement-dependent portion of the damping can be adjusted by way of the pitch of the threads 48, 50.
In the case of both above-described damping arrangements, the intensity of the basic damping can be predetermined by adjusting the lower damping part 18, for which purpose the threaded rings 26, 28 are appropriately screwed on the internal thread 30 of the end section of the housing 14.
Both above-described damping arrangements operate completely without static friction. One thus has effective damping even for low oscillation amplitudes, damping taking place in a speed-dependent manner. | Arrangement for damping linear movements intended for use on a safety valve. An arrangement for damping linear movements of the valve spindle (10) of a safety valve of small amplitude and high frequency comprises two counter-rotatable damping parts (18, 36) with intermeshing wall (22, 24, 32) which delimit narrow working gaps (44, 46) containing a high-viscosity silicone grease. The linear intake movement is converted by a threaded drive (12, 40) into a rotary movement during which the silicone grease (47) in the working gaps (44, 46) is subjected to shear forces and eliminates the unwanted energy by virtue of its internal friction. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and device for measuring blood flow rate in a blood access. Blood is taken out from the body of a mammal to an extracorporeal blood circuit through a blood access, via needles or a catheter.
2. Description of the Related Art
There are several types of treatments in which blood is taken out in an extracorporeal blood circuit. Such treatments involve, for example, hemodialysis, hemofiltration, hemodiafiltration, plasmapheresis, blood component separation, blood oxygenation, etc. Normally, blood is removed from a blood vessel at an access site and returned to the same blood vessel or at another location in the body.
In hemodialysis and similar treatments, an access site is commonly surgically created in the nature of a fistula. Blood needles are inserted in the area of the fistula. Blood is taken out from the fistula via an arterial needle and blood is returned to the fistula via a venous needle.
A common method of generating a permanent access site having capability of providing a high blood flow and being operative during several years and even tens of years, is the provision of an arterio-venous fistula. It is produced by operatively connecting the radial artery to the cephalic vein at the level of the forearm. The venous limb of the fistula thickens during the course of several months, permitting repeated insertion of dialysis needles.
An alternative to the arterio-venous fistula is the arterio-venous graft, in which a connection is generated from, for example, the radial artery at the wrist to the basilic vein. The connection is made with a tube graft made from autogenous saphenous vein or from polytetrafluorethylene (PTFE, Teflon). The needles are inserted in the graft.
A third method for blood access is to use a silicon, dual-lumen catheter surgically implanted into one of the large veins.
Further methods find use in specific situations, like a no-needle arterio-venous graft consisting of a T-tube linked to a standard PTFE graft. The T-tube is implanted in the skin. Vascular access is obtained either by unscrewing a plastic plug or by puncturing a septum of said T-tube with a needle. Other methods are also known.
During hemodialysis, it is desirable to obtain a constant blood flow rate of 150-500 ml/min or even higher, and the access site must be prepared for delivering such flow rates. The blood flow in an AV fistula is often 800 ml/min or larger, permitting delivery of a blood flow rate in the desired range.
In the absence of a sufficient forward blood flow, the extracorporeal circuit blood pump will take up some of the already treated blood entering the fistula via the venous needle, so called access or fistula recirculation, leading to poor treatment results.
The most common cause of poor flow with AV fistulas is partial obstruction of the venous limb due to fibrosis secondary to multiple venipunctures. Moreover, stenosis causes a reduction of access flow.
When there is a problem with access flow, it has been found that access flow rate often exhibit a long plateau time period with reduced but sufficient access flow, followed by a short period of a few weeks with markedly reduced access flow leading to recirculation and ultimately access failure. By constantly monitoring the evolution of the access flow during consecutive treatment sessions, it is possible to detect imminent access flow problems.
Several methods have been suggested for monitoring recirculation and access flow. Many of these methods involve injection of a marker substance in blood, and the resultant recirculation is detected. The methods normally involve measurement of a property in the extracorporeal blood circuit. Examples of such methods can be found in U.S. Pat. No. 5,685,989, U.S. Pat. No. 5,595,182, U.S. Pat. No. 5,453,576, U.S. Pat. No. 5,510,716, U.S. Pat. No. 5,510,717, U.S. Pat. No. 5,312,550, etc.
Such methods have the disadvantage that they cannot detect when the access flow has decreased to such an extent that recirculation is at risk, but only when recirculation prevails. Moreover, it is a drawback that injection of a substance is necessary.
A noninvasive technique that allows imaging of flow through AV grafts is color Doppler ultrasound. However, this technique requires expensive equipment.
The measurement of access flow rate necessitates the reversal of the flows in the extracorporeal circuit. A valve for such reversal is shown in i.a. U.S. Pat. No. 5,605,630 and U.S. Pat. No. 5,894,011. However, these valve constructions comprise dead ends in which blood may stand still for a long time and coagulate, which is a drawback.
BRIEF SUMMARY OF INVENTION
An object of the present invention is to provide a method and a device for measuring the access flow rate without interfering with the blood and without injecting a substance in blood.
Another object of the invention is to provide a method and a device for measuring access flow rate without measuring on the blood in the extracorporeal blood circuit or in the access or blood vessel.
According to the invention, it is required to reverse the blood flow through the access. Thus, a further object of the invention is to provide a valve for reversing the blood flow.
A still further object of the invention is to provide a method for determining when the blood flow rate is so small that risk for recirculation prevails.
These objects are achieved with a method and an apparatus for estimating fluid flow rate (Qa) in a fluid flow access, comprising removing a first fluid flow from said access at a removal position to an external flow circuit comprising a dialyzer having a semipermeable membrane, said first fluid flow passing along said membrane at one side thereof and a dialysis fluid being emitted from the other side thereof, and returning said first fluid flow from said external flow circuit to said access at a return position downstream of said removal position, measuring a first variable which is essentially proportional to a concentration (Cd norm) of a substance in said dialysis fluid emitted from the dialyzer, reversing the removal position with the return position and measuring a second variable which is essentially proportional to the concentration (Cd rev) of said substance in said dialysis fluid in the reversed position; and calculating the fluid flow rate (Qa) in said flow access from said measured concentrations.
Preferably, the calculation of the fluid flow rate in said flow access takes place by calculating the ratio between the first and the second variable and using the formula:
Cd norm/Cd rev=1+K/Qa, in which Cd norm and Cd rev are values proportional to the concentrations of said substance in the dialysis fluid in the normal and reversed positions, respectively, and K is the clearance of the dialyzer and Qa is the access flow rate.
The blood flow access may be in a mammal for obtaining access to a blood vessel, such as a hemodialysis access in the nature of an arterio-venous shunt or fistula. In the latter case, the dialyzer clearance K is replaced by the effective dialyzer clearance Keff obtained by taking into account a cardiopulmonary recirculation and in the normal position.
The substance is preferably selected from the group of: urea, creatinine, vitamin B12, beta-two-microglobuline and glucose, or may be an ion selected from the group of: Na + , Cl − , K + , Mg ++ , Ca ++ , HCO 3 − , acetate ion, or any combination thereof as measured by conductivity; and wherein said concentration is measured as the concentration difference between the outlet and the inlet of the dialyzer, if applicable.
It is possible to measure the actual concentration of the substance. However, since only the ratio between the concentrations in the normal and the reversed position, respectively, is needed, it is possible to measure a value, which is proportional to the concentration of said substance, whereby said value is used in place of said concentration. Said property may be the blood concentration of said substance in the external circuit, either before or after the dialyzer. Alternatively, the relative whole body efficiency (Kwh/V) may be used, as explained in more detail below.
The effective clearance Keff may be obtained by the equation Keff=Qd*Cd/Cs, where Qd is the flow of dialysis fluid emitted from the dialyzer, Cd is the concentration of said substance in said dialysis fluid and Cs is the concentration of said substance in systemic venous blood.
A method of measuring the concentration (Cs) of said substance in systemic venous blood comprises the steps of: stopping the blood flow in the external flow circuit for a time period sufficient to allow the cardiopulmonary circulation to equalize; starting the blood flow in the external flow circuit with a slow speed to fill the arterial line with fresh blood before the measurement; and measuring the equalized concentration of said substance in the dialysis fluid at a low dialysate flow rate or at isolated ultrafiltration. It is advantageous to make the measurement of the effective clearance at the initiation of the treatment.
The concentration (Cs) of said substance in systemic venous blood may be estimated by: calculating a whole body mass of urea (Murea) in the body of the patient, estimating or measuring the distribution volume (V) of urea in the body of the patient; and estimating the concentration (Cs) of said substance in the blood by dividing the whole body mass of urea with the distribution volume. In this way, the mean concentration of urea in the whole body is obtained. However, the mean concentration in the whole body is slightly higher than the urea concentration in the systemic blood, except at the start of the treatment. Thus, this calculation should preferably be done or be extrapolated to the start of the treatment.
It is possible to discriminate between the condition when access or fistula recirculation has developed and not. A method for that purpose would be: changing the blood flow rate (Qb); monitoring the concentration of said substance in the dialysate emitted from the dialyzer; and detecting a possible fistula recirculation in the normal position by correlating a change in said concentration to said change of the blood flow rate.
Preferably, the blood flow rate is decreased and a corresponding decrease in the urea concentration is monitored, and the absence of such a decrease being indicative of fistula recirculation.
BRIEF DESCRIPTION OF DRAWINGS
Further objects, advantages and features of the invention appears from the following detailed description of the invention with reference to specific embodiments of the invention shown on the drawings, in which
FIG. 1 is a partially schematic view of a forearm of a patient provided with an AV fistula;
FIG. 2 is a schematic diagram of an extracorporeal dialysis circuit;
FIG. 3 is a schematic diagram of the blood flow circuit in a patient and in the attached extracorporeal blood circuit;
FIG. 4 is a schematic diagram similar to FIG. 3 , but with the extracorporeal circuit in an alternative reversed position;
FIG. 5 is a schematic diagram of a blood flow circuit including a switch valve;
FIG. 6 is a diagram of the dialysis fluid urea concentration versus time, including a portion with reversed flow access according to the invention;
FIG. 7 is a schematic diagram similar to the diagram of FIG. 5 comprising an alternative valve arrangement;
FIG. 8 is schematic diagram similar to the diagram of FIG. 7 showing the valve arrangement in an idle position;
FIG. 9 is schematic diagram similar to the diagram of FIG. 7 showing the valve arrangement in a reversed position;
FIG. 10 is a schematic diagram similar to FIG. 5 with the pump in an alternative position;
FIG. 11 is a diagram showing calculations with relative whole body efficiency;
FIG. 12 is a cross-sectional view of a valve housing to be used in the schematic diagram of FIGS. 5 and 7 to 10 ;
FIG. 13 is a bottom view of a valve member intended to be inserted in the valve housing of FIG. 12 ; and
FIG. 14 is a partially schematic plan view of the valve housing of FIG. 12 .
DETAILED DESCRIPTION OF INVENTION
For the purpose of this description, an access site is a site in which a fluid in a tube can be accessed and removed from and/or returned to the tube. The tube may be a blood vessel of a mammal, or any other tube in which a fluid is flowing. The access flow rate is the flow rate of the fluid in the tube or blood vessel immediately upstream of the access site or removal position.
FIG. 1 discloses a forearm 1 of a human patient. The forearm 1 comprises an artery 2 , in this case the radial artery, and a vein 3 , in this case the cephalic vein. Openings are surgically created in the artery 2 and the vein 3 and the openings are connected to form a fistula 4 , in which the arterial blood flow is cross-circuited to the vein. Due to the fistula, the blood flow through the artery and vein is increased and the vein forms a thickened area downstream of the connecting openings. When the fistula has matured after a few months, the vein is thicker and may be punctured repeatedly. Normally, the thickened vein area is called a fistula.
An arterial needle 5 is placed in the fistula, in the enlarged vein close to the connected openings and a venous needle 6 is placed downstream of the arterial needle, normally at least five centimeters downstream thereof.
The needles 5 and 6 are connected to a tube system 7 , shown in FIG. 2 , forming an extracorporeal circuit comprising a blood pump 8 , such as a dialysis circuit. The blood pump propels blood from the blood vessel, through the arterial needle, the extracorporeal circuit, the venous needle and back into the blood vessel.
The extracorporeal blood circuit 7 shown in FIG. 2 further comprises an arterial clamp 9 and a venous clamp 10 for isolating the patient from the extracorporeal circuit should an error occur.
Downstream of pump 8 is a dialyzer 11 , comprising a blood compartment 12 and a dialysis fluid compartment 13 separated by a semipermeable membrane 14 . Further downstream of the dialyzer is a drip chamber 15 , separating air from the blood therein.
Blood passes from the arterial needle past the arterial clamp 9 to the blood pump 8 . The blood pump drives the blood through the dialyzer 11 and further via the drip chamber 15 and past the venous clamp 10 back to the patient via the venous needle. The drip chamber may comprise an air detector, adapted to trigger an alarm should the blood emitted from the drip chamber comprise air or air bubbles. The blood circuit may comprise further components, such as pressure sensors etc.
The dialysis fluid compartment 13 of the dialyzer 11 is provided with dialysis fluid via a first pump 16 , which obtains dialysis fluid from a source of pure water, normally RO-water, and one or several concentrates of ions, metering pumps 17 and 18 being shown for metering such concentrates. The preparation of dialysis fluid is conventional and is not further described here.
An exchange of substances between the blood and the dialysis fluid takes place in the dialyzer through the semipermeable membrane. Notably, urea is passed from the blood, through the semipermeable membrane and to the dialysis fluid present at the other side of the membrane. The exchange may take place by diffusion under the influence of a concentration gradient, so called hemodialysis, and/or by convection due to a flow of liquid from the blood to the dialysis fluid, so called ultrafiltration, which is an important feature of hemodiafiltration or hemofiltration.
From the dialysis fluid compartment 13 of the dialyzer is emitted a fluid called the dialysate, which is driven by a second pump 19 via a urea monitor 20 to drain. The urea monitor continuously measures the urea concentration in the dialysate emitted from the dialyzer, to provide a dialysate urea concentration curve during a dialysis treatment. Such urea concentration curve may be used for several purposes, such as obtaining a total body urea mass, as described in WO 9855166, and to obtain a prediction of the whole body dialysis dose Kt/V as also described in said application. The content of WO 9855166 is incorporated in the present specification by reference.
As described above, the present invention provides a method of non-invasively measuring the access flow in the fistula immediately before the arterial needle, using the urea monitor and the dialysis circuit as shown in FIG. 2 .
By measuring the dialysis urea concentration during normal dialysis and then reversing the positions of the needles and measuring the dialysis urea concentration with the needles in the reversed position, it is possible to calculate the blood flow in the blood access, without the addition of any substance to blood or the dialysis fluid.
FIG. 3 shows a simplified schematic diagram of the blood vessel circuit of a patient and a portion of the dialysis circuit according to FIG. 2 . The patient blood circuit comprises the heart, where the right chamber of the heart is symbolized by an upper pump 21 and the left chamber of the heart is symbolized by a lower pump 22 . The lungs 23 are located between the upper and lower pump. From the outlet of the left chamber pump 22 of the heart, the blood flow divides into a first branch 24 leading to the access 25 , normally in the left forearm of the patient, and a second branch 26 leading to the rest of the body, such as organs, other limbs, head, etc. symbolized by a block 27 . Blood returning from the body from the organs etc., i.e. from block 27 , combines with blood returning from the access and enters the right chamber pump 21 .
The cardiac output flow rate is defined as Qco and the flow rate of the access is defined as Qa, which means that Qco−Qa enters the block 27 . The venous blood returning from block 27 before being mixed with blood from the access, the systemic venous blood, has a urea concentration of Cs. The blood leaving the left chamber pump 22 has a urea concentration of Ca equal to that passing out to the access 25 as well as to the block 27 .
For measuring the access flow rate, it is necessary to reverse the flow through the arterial and venous needles. One way of achieving that is to reverse the needles manually.
Alternatively, FIG. 5 shows a valve 28 for performing the same operation. The arterial needle 5 is connected to an arterial inlet line 29 of the valve and the venous needle 6 is connected to a venous inlet line 30 of the valve. The blood pump is connected to a first outlet line 31 of the valve and the returning blood from the dialyzer 11 is connected to a second outlet line 32 of the valve.
The valve comprises a valve housing and a pivotable valve member 33 , which is pivotable from the normal position shown on the drawing to a reverse position pivoted 900 in relation to the normal position.
In the normal position shown in FIG. 5 , the arterial needle 5 is connected to the blood pump 8 and the venous needle 6 is connected to the outlet of the dialyzer, via the drip chamber, see FIG. 2 . In the reversed position, the arterial needle 5 is connected to the outlet of the dialyzer and the venous needle 6 is connected to the blood pump 8 , as required.
An alternative design of the valve arrangement is shown in FIGS. 7 , 8 and 9 . In the embodiment of FIG. 7 , the arterial line 29 is connected to an enlarged opening 29 a and the venous outlet line 30 is connected to an enlarged opening 30 a , the openings being arranged in the valve housing 28 a diametrically opposite to each other. Two enlarged openings 31 a and 32 a are arranged in the valve housing 28 a diametrically opposite each other and displaced 90° in relation to enlarged openings 29 a and 30 a . The pivotable valve member 33 a is normally arranged as shown in FIG. 7 and forms a partition dividing the valve chamber in two semi-circular portions. The valve member has a width, which is smaller than the peripheral dimension of the enlarged openings. The valve member is pivotable 900 to a reverse position, shown in FIG. 9 , in which the blood flows through the arterial and venous needles are reversed.
During its movement from the normal to the reversed position, the valve member 33 a passes through an idle position shown in FIG. 8 , in which all four enlarged openings are interconnected, because the width of the valve member is smaller than the peripheral dimension of the enlarged openings. By this idle position, harm to blood cells may be avoided. Such harm may be caused by high shear stresses, which may occur if the inlet line 31 to the blood pump or the outlet line 32 from the dialyzer is completely occluded. By means of the idle position, another advantage is obtained, that the blood needles are not exposed to rapid change of flows, which in some instances even may result in dislocation of the needles. When the valve member is moved from the normal position to the idle position, the flow through the needles change from the normal flow of, for example, 250 ml/min to essentially zero flow. The valve member may be placed in the idle position for some seconds. Then, the valve member is moved to the reversed position, and the flows through the needles are changed from essentially zero flow to −250 ml/min. In this way, a gentler switch between normal and reversed flows may be obtained.
It is noted, that the positions of the openings and the valve member may be different so that the pivotal movement may be less than or more than 90°. Moreover, the openings need not be arranged diametrically in order to achieve the desired operation. Furthermore, the dimensions of the enlarged openings in relation to the tubes and lines are not in scale, but the diameter of the enlarged openings is rather of the same dimension as the tube inner diameter, as appears more clearly below.
It is noted that the valve is constructed to have as few dead end portions as possible, in which the blood may stand still and coagulate. From the drawing, it is appreciated that no portion of the valve has a dead end construction in any position of the valve body.
Furthermore, another schematic diagram incorporating a valve is shown in FIG. 10 . FIG. 10 differs from FIG. 5 only in the placement of the pump 8 a , which in the embodiment according to FIG. 10 is placed between the arterial needle 5 and the valve 28 . In this manner, the pressure across the valve body 33 is less compared to the embodiment according to FIG. 5 . The operation is somewhat different. The blood pump is stopped, and the valve is put in the reversed position. Finally, the pump is started and pumping the blood in the opposite direction by reversing the rotational direction of the pump.
In order to ascertain that no air is introduced into the patient in either position of the valve, it may be advantageous to add an air detector 34 and 35 immediately before each of the arterial and venous needle, or at least before the arterial needle. The air detectors trigger an alarm should they measure air bubbles in the blood given back to the blood vessel. Normally, the air detector in the drip chamber is sufficient for this purpose.
The detailed construction of a valve intended to be used in the present invention, is disclosed in FIGS. 12 , 13 and 14 . The valve comprises a valve housing 36 comprising two inlet connectors and two outlet connectors. All four connectors open into cylindrical valve chamber 41 , the four openings being displaced 90° in relation to each other.
As shown in FIG. 14 , the valve comprises a blood inlet connector 37 connected to the arterial needle 5 and a blood outlet connector 38 connected to the venous needle 6 . The connector portions are arranged as male Luer connectors to be connected to flexible tubes ending with a female Luer connector.
Furthermore, the valve comprises a circuit outlet connector 39 connected to the blood pump 8 and a circuit inlet connector 40 connected to the dialyzer outlet. The connector portions 39 and 40 are arranged as female Luer connectors to mate with male Luer connectors of the circuit.
As appears from FIG. 12 , the cylindrical valve chamber 41 is closed at the bottom. From the top, a valve member 42 may be introduced into the cylindrical valve chamber. The valve member 42 comprises a valve partition 43 as appears from FIG. 13 .
The valve member also comprises an operating wing 44 , by means of which the valve member may be pivoted 900 between a normal position, in which the valve partition 43 is situated as shown by dotted lines in FIG. 14 , and a reversed position. The pivotal movement is limited by a shoulder 45 of the valve member 42 , which cooperates with a groove 46 in the valve housing. The shoulder 45 is provided with a protrusion 46 a that cooperates with two recesses 47 and 48 in the normal position and reverse position, respectively, to maintain the valve member in either position. The groove 46 may be provided with a third recess (not shown in the drawing) in order to define said idle position. Such a third recess is positioned in the middle between the two recesses 47 and 48 .
The valve member and housing are provided with suitable sealing to ensure safe operation. The operation of the valve is evident from the above description.
By studying the theoretical dialysate urea concentrations resulting from a given dialyzer clearance K, a given access blood flow Qa and a given blood urea concentration Cs in the systemic venous blood returning from the body, it is found that the effective urea clearance Keff of the dialyzer, taking the cardiopulmonary recirculation into account, is needed for the calculation of access flow. The effective clearance can be measured, for example as described in EP 658 352, the contents of which is incorporated in the present application by reference.
Alternatively, the effective clearance can be calculated from simultaneous systemic venous blood Cs and dialysate Cd measurements of urea concentrations, such as by blood samples.
The systemic blood urea concentration Cs may be measured by the so called stop flow—slow flow technique, where the blood flow is substantially stopped for a couple of minutes to allow the cardiopulmonary recirculation to equalize. Thereafter, the pump is run slowly to fill the arterial line with fresh blood before taking the blood sample. The urea concentration in the so obtained blood sample is equal to the urea concentration Cs in the systemic venous blood returning from the body to the heart.
Alternatively to taking a blood sample, the dialysis fluid flow at the other side of the membrane is stopped and the slowly flowing blood is allowed to equalize with the dialysate at the other side of the membrane, whereupon the urea concentration of the dialysate is measured to obtain the systemic venous blood urea concentration Cs.
A further method to obtain effective clearance is described in WO 9929355. According to the invention described in WO 9929355, the systemic blood concentration Cs is measured before or at the initiation of the treatment, for example by stop flow—slow flow technique with blood sample or equalization as described above. After obtaining valid dialysate urea concentration values Cd from a urea monitor connected to the dialyzer outlet line, the initial dialysate urea concentration Cdinit at the start of the treatment is extrapolated by the dialysate urea curve obtained. The content of WO 9929355 is incorporated herein by reference.
A still further method of obtaining systemic blood urea concentration Cs is to calculate the urea mass Mwh in the whole body and extrapolate the urea mass to the start of the treatment. By dividing the whole body urea mass Mwh with the distribution volume V, the systemic blood urea concentration Cs at the start of the treatment is obtained.
By dividing the dialysate urea concentration Cd with the systemic blood urea concentration Cs and multiplying with the dialysate flow rate Qd, the effective clearance Keff is obtained. It is advantageous to measure the effective clearance Keff at the initiation of the treatment.
Furthermore, in the method of the invention, the blood flows in the arterial and venous needles are reversed. The dialysate urea concentrations in the two cases with normal position of the needles and with reverse position of the needles may be calculated as follows, with reference to FIGS. 3 and 4 .
The blood urea concentration Cs in the venous blood returning from the body is assumed unchanged when the lines are reversed, and the dialyzer clearance K is also assumed unchanged. For simplicity ultrafiltration is assumed to be zero, but it is also possible to handle a nonzero UF.
The following notations are used:
Qco—Cardiac Output Qa—Access flow Qb—Blood flow in extracorporeal circuit Qd—Dialysate flow K—Dialyzer clearance Keff—Effective dialyzer clearance Cs—Blood urea concentration in systemic venous blood returning from the body Ca—Blood urea concentration in the access Cb—Blood urea concentration at the dialyzer inlet Cd—Dialysate urea concentration
The definition of clearance is:
K =(removed urea)/ Cb=Qd*Cd/Cb (1)
Consider first the case in which Qa>Qb and the needles are in the normal position. In this case Cb=Ca.
Removal from blood must equal appearance in the dialysate so that
K*Ca=Qd*Cd (2)
A mass balance for urea at the point V, see FIG. 3 , when mixing the venous return blood with the blood from the access gives:
Ca*Qco=Cs *( Qco−Qa )+ Ca *( Qa−K ) (3)
Thus, we obtain a relation between Ca and Cs.
By combining equations 2 and 3 we obtain:
Cd =( K/Qd )* Cs/[ 1 +K /( Qco−Qa )] (4)
The definition of effective clearance Keff implies that Cs should be used in the denominator instead of Cb as normally used in dialyzer clearance, which means that
Keff=K *( Cb/Cs )= K/[ 1 +K /( Qco−Qa )] (5)
If we now turn to the case with reversed lines, see FIG. 4 , we still have that what is removed from the blood must enter the dialysate, so that in this case
K*Cb=Qd*Cd (6)
The flow in the fistula between the needles will be Qa+Qb and we can calculate the blood urea concentration at the dialyzer inlet from a urea mass balance at the point P where the dialyzed blood enters the access again
Cb *( Qb−K )+ Ca*Qa=Cb *( Qb+Qa ) (7)
We also have the mass balance at the point Q where the venous return blood meets the dialyzed blood in the access return flow:
Ca*Qco=Cs *( Qco−Qa )+ Cb*Qa (8)
By eliminating Ca and Cb we get
Cd =( K/Qd )* Cs/[ 1+( Qco/Qa )* K /( Qco−Qa )] (9)
Since Cs, K and Qd in the two cases are unchanged, it is possible to obtain the ratio of dialysate urea concentrations:
Cd
norm
/
Cd
rev
=
1
+
(
K
/
Qa
)
/
[
1
+
K
/
(
Qco
-
Qa
)
]
=
=
1
+
Keff
/
Qa
(
10
)
In practice, the two dialysate urea concentrations are probably best found by a curve fit to the dialysate urea curves before and after the switch of lines, with an extrapolation to the time of switching from the respective side, see FIG. 6 , which shows the urea concentration Cd of the dialysate during a normal hemodialysis treatment.
During a time period of about 10 minutes, marked with a ring in FIG. 6 , the arterial and venous needles are reversed. After an initial time period for allowing the urea monitor to measure accurately, the urea concentration with reversed lines is approximately 0.8 times the original urea concentration, which means that Cdnorm/Cdrev=1.25. Thus, if Keff is 200 ml/min, as measured with the needles in the normal position or estimated as described above, the access flow is 800 ml/min.
The effective clearance may also be obtained as a rough estimate from blood and dialyzer flows and dialyzer characteristics, e.g. from the dialyzer date sheet.
In the present specification, there are used three different clearances, namely dialyzer clearance, effective clearance and whole body clearance. If dialyzer clearance is 250 ml/min for a certain blood flow rate and dialysate flow rate, the effective clearance is normally 5 to 10% lower, such as 230 ml/min. The whole body clearance is still 5 to 15% lower, such as 200 ml/min. The dialyzer clearance is the clearance as measured directly on the dialyzer. The effective clearance is the clearance also taking into account the cardio-pulmonary recirculation. Finally, the whole body clearance is the effective clearance further taking into account other membranes in the body restricting the flow of urea from any part of the body to the dialysate. The concept of whole body clearance is described in WO 9855166, the content of which is herewith incorporated by reference.
The effective clearance used in the formula may also be obtained from a measurement according to the method described in EP 658 352 mentioned above, with the needles in the normal position. This will give a measure of the effective plasma water urea clearance, which then has to be converted to whole blood clearance. The method of EP 658 352 essentially comprises that the conductivity of the dialysis fluid upstream of the dialyzer is increased by for example 10% and then returned to the original value. The result at the outlet side of the dialyzer is measured and results in a measure of the effective clearance Keff of the dialyzer.
Alternatively, the effective clearance may be calculated according to equation Kef f=Qd*Cd/Cs. The systemic venous urea concentration may be measured at the same time as the dialysate urea concentration Cd, or by the methods described above.
Another method would be to use the value of total body urea mass Murea obtained by the method according to WO 9855166, mentioned above. By obtaining the urea distribution volume V by Watsons formula or any other method, the venous urea concentration would be approximately:
Cs=Murea/V (11)
In the method of WO 9855166, the relative whole body efficiency of the dialyzing process Kwb/V is obtained. Note, that whole body clearance is used, as indicated by the subscript wb. According to said WO 9855166, urea concentration is proportional to the relative whole body efficiency according to the formula:
Kwb/V =( Qd*Cd )/ m (12)
Thus, if (Kwb/V) is used instead of Cd in the above equation (10), a similar result is obtained, if it is presumed that m is constant, i.e. the measurement must be extrapolated to the same time instance:
( Kwb/V )norm/( Kwb/V )rev=1 +Keff/Qa (13)
As is mentioned in said WO 9855166, it is possible to calculate the relative whole body efficiency only from dialysate urea measurement. Since we are interested only in the ratio in the normal and reversed position, we do not need to calculate the actual Kwh.
FIG. 11 shows a plot of the relative whole body efficiency K/V (min −1 ). The period with reversed lines is shown inside a circle. In all other respects, the same discussion applies as is given above.
The calculations above assume that the extracorporeal blood flow rate Qb does not exceed the access flow rate Qa. If this is the case there will be access recirculation and the flow in the access will be reversed when the needles are in the normal position. The calculation of dialysate urea concentration is unchanged for the needles in reversed position, but has to be modified for the needles in normal position. Calculations corresponding to those above show that the ratio above between dialysate urea concentrations for normal and reversed needle positions will be:
Cd norm/ Cd rev=1 +Keff/Qb (14)
where Keff is the effective clearance with the effect of recirculation included, that is with the needles in the normal position.
The only difference is that the calculation will now give the extracorporeal blood flow Qb instead of the access flow. This blood flow is known, so in practice this means that when the result is an access flow rate Qa close to the blood flow rate Qb, recirculation should be suspected, and this always means that the access has to be improved.
Keff/Qb is a figure lower than one, normally for example 0.6-0.9. Keff/Qa should be considerably lower, for example 0.1-0.4. Thus, when Cd norm/Cd rev approaches or is lower than a predetermined number, such as 1.2 or 1.5, further calculations should be done for determining if access recirculation is present.
A simple procedure is to decrease the blood flow Qb somewhat. If the dialysate concentration then decreases, this means that there is no access or fistula recirculation at least at the lower blood flow.
The above calculations can also be made for the situation where ultrafiltration is present. However, it is a simple measure to reduce the ultrafiltration to zero during the measurement interval. Moreover, the error induced by ultrafiltration is small and may be neglected.
The measurement should be performed during a time interval, which is considerably larger than 30 seconds so that cardio-pulmonary recirculation has been developed. The measurement time for obtaining valid results may be 5 minutes with the needles reversed, while measurements with the needles in correct position may be done in 5 minutes or continuously during the treatment.
The method is also applicable to the methods of treatment comprising infusion of a dialysis solution to the blood before or after the dialyzer, called hemofiltration and hemodiafiltration. The result is the same as given above.
If the access is a venous catheter, there is no cardio-pulmonary recirculation and the calculation becomes simpler. The result is the same, except that the effective clearance Keff is replaced by the dialyzer clearance K, since the systemic venous urea concentration Cs becomes the same as the dialyzer inlet urea concentration Cb.
It should be noted that all flow rates, clearances and urea concentrations in the calculations relate to whole blood. Approximately 93% of plasma is water, depending on the protein concentration, and about 72% of erythrocytes is water. Depending on the hematocrit value, the blood water volume is 10-13% lower than the volume of whole blood, see for example Handbook of Dialysis, Second Edition, John T. Daugirdas and Todd. S Ing, 1994, page 18.
The effective urea clearance obtained according to EP 658 352 relates to blood water, and must therefore be increased by 10-13% before being used in the present formulas. Blood urea concentration values obtained from a laboratory relate in general to plasma, and must therefore be decreased by about 7% in order to relate to whole blood.
Alternatively, all urea concentrations, flow rates and clearances may be used as relating to blood water. The effective clearance is then used unchanged, but the calculated access flow will relate to blood water, and has to be increased by 10-13% to relate to whole blood.
The invention has been described above with reference to use in the human body and using urea as a marker for measuring access flow. However, any other substance present in blood and which can be measured at the dialysate side of the dialyzer may be used according to the invention, such as creatinine, vitamin B12, beta-two-microglobuline, NaCl or any combination of ions. Another alternative is to measure conductivity.
It is also possible to measure a property proportional to the concentration, since it is the ratio that is involved in the equations. Thus, urea concentration may be measured by measuring conductivity differences after passing the urea containing fluid through a urease column, and such conductivity difference can be used directly in place of the concentration values in the equations.
Other indirect methods of measuring any of the above-mentioned substances concentrations may be used as long as the measurements are made at the dialysate side of the dialyzer. Another alternative is to measure the blood urea concentrations by any known method, either before or after the dialyzer, since these concentrations are proportional to the concentrations in the formulas.
The invention has been described above with reference to use in the human body. However, the invention can be used in any tube system where a fluid is passed and a portion thereof is taken out for dialysis, such as in beer or wine production. | A switch valve for use in an extracorporeal blood flow circuit comprises a valve housing having a chamber, four openings communicating with the chamber, and a valve member located in the valve chamber. A first opening is to be connected to a patient via an arterial cannula, a second opening is to be connected to a patient via an venous cannula, a third opening is to be connected to a first inlet/outlet of a blood treatment device, and a fourth opening is to be connected to a second inlet/outlet of a blood treatment device. The valve member is movable within the valve housing to fluidly connect the first opening to either the third or the fourth opening and to fluidly connect the second opening to either the third or the fourth opening. The width of the valve member is smaller than a peripheral dimension of the openings. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates generally to magnetic recording heads and more particularly to a method of making thin-film magnetic heads for imprinting time based servo patterns on a magnetic media.
BACKGROUND OF THE INVENTION
[0002] While a variety of data storage mediums are available, magnetic tape remains a preferred forum for economically storing large amounts of data. In order to facilitate the efficient use of this media, magnetic tape will have a plurality of data tracks extending in a transducing direction of the tape. Once data is recorded onto the tape, one or more data read heads will read the data from those tracks as the tape advances, in the transducing direction, over the read head. It is generally not feasible to provide a separate read head for each data track, therefore, the read head(s) must move across the width of the tape (in a translating direction), and center themselves over individual data tracks. This translational movement must occur rapidly and accurately.
[0003] In order to facilitate the controlled movement of a read head across the width of the media, a servo control system is generally implemented. The servo control system consists of a dedicated servo track embedded in the magnetic media and a corresponding servo read head which correlates the movement of the data read heads.
[0004] The servo track contains data, which when read by the servo read head is indicative of the relative position of the servo read head with respect to the magnetic media in a translating direction. In one type of traditional arrangement, the servo track was divided in half. Data was recorded in each half track, at different frequencies. The servo read head was approximately as wide as the width of a single half track. Therefore, the servo read head could determine its relative position by moving in a translating direction across the two half tracks. The relative strength of a particular frequency of data would indicate how much of the servo read head was located within that particular half track.
[0005] While the half track servo system is operable, it is better suited to magnetic media where there is no contact between the storage medium and the read head. In the case of magnetic tape, the tape actually contacts the head as it moves in a transducing direction. Both the tape and the head will deteriorate as a result of this frictional engagement; thus producing a relatively dirty environment. As such, debris will tend to accumulate on the read head which in turn causes the head to wear even more rapidly. Both the presence of debris and the wearing of the head have a tendency to reduce the efficiency and accuracy of the half track servo system.
[0006] Recently, a new type of servo control system was created which allows for a more reliable positional determination by reducing the signal error traditionally generated by debris accumulation and head wear. U.S. Pat. No. 5,689,384, issued to Albrect et al. on Nov. 19, 1997, introduces the concept of a timing based servo pattern, and is herein incorporated by reference in its entirety.
[0007] In a timing based servo pattern, magnetic marks (transitions) are recorded in pairs within the servo track. Each mark of the pair will be angularly offset from the other. Virtually any pattern, other than parallel marks, could be used. For example, a diamond pattern has been suggested and employed with great success. The diamond will extend across the servo track in the translating direction. As the tape advances, the servo read head will detect a signal or pulse generated by the first edge of the first mark. Then, as the head passes over the second edge of the first mark, a signal of opposite polarity will be generated. Now, as the tape progresses no signal is generated until the first edge of the second mark is reached. Once again, as the head passes the second edge of the second mark, a pulse of opposite polarity will be generated. This pattern is repeated indefinitely along the length of the servo track. Therefore, after the head has passed the second edge of the second mark, it will eventually arrive at another pair of marks. At this point, the time it took to move from the first mark to the second mark is recorded. Additionally, the time it took to move from the first mark (of the first pair) to the first mark of the second pair is similarly recorded.
[0008] By comparing these two time components, a ratio is determined. This ratio will be indicative of the position of the read head within the servo track, in the translating direction. As the read head moves in the translating direction, this ratio will vary continuously because of the angular offset of the marks. It should be noted that the servo read head is relatively small compared to the width of the servo track. Ideally, the servo head will also be smaller than one half the width of a data track. Because position is determined by analyzing a ratio of two time/distance measurements, taken relatively close together, the system is able to provide accurate positional data, independent of the speed (or variance in speed) of the media.
[0009] By providing more than one pair of marks in each grouping, the system can further reduce the chance of error. As the servo read head scans the grouping, a known number of marks should be encountered. If that number is not detected, the system knows an error has occurred and various corrective measures may be employed.
[0010] Of course, once the position of the servo read head is accurately determined, the position of the various data read heads can be controlled and adjusted with a similar degree of accuracy.
[0011] When producing magnetic tape (or any other magnetic media) the servo track is generally written by the manufacturer. This results in a more consistent and continuous servo track, over time. To write the timing based servo track described above, a magnetic recording head bearing the particular angular pattern as its gap structure, must be utilized. As it is advantageous to minimize the amount of tape that is dedicated to servo tracks, to allow for increased data storage, and it is necessary to write a very accurate pattern, a very small and very precise servo recording head must be fabricated.
[0012] Historically, servo recording heads having a timing based pattern have been created utilizing known plating and photolithographic techniques. A head substrate is created to form the base of the recording head. Then, a pattern of photoresist is deposited onto that substrate. The photoresist pattern essentially forms the gap in the head. Therefore, the pattern will replicate the eventual timing based pattern. After the pattern has been applied a magnetically permeable material such as NiFe is plated around the photoresist pattern. Once so formed, the photoresist is washed away leaving a head having a thin film magnetic substrate with a predefined recording gap.
[0013] Alternatively, the ion milling is used to form a first layer having a relatively large gap. A pattern of photoresist is applied in an inverse of the above described pattern. That is, photoresist is applied everywhere except where the timing based pattern (gap) is to be formed. Ion milling is used to cut the gap through the first layer. Then an additional layer of the magnetically permeable material is deposited by plating over the first layer and a narrow gap is formed into this layer by the above described photolithographic process. This approach produces a more efficient head by creating a thicker magnetic pole system.
[0014] While the above techniques are useful in producing timing based recording heads, they also limit the design characteristics of the final product. In the first method, only materials which may be plated can be utilized, such as NiFe (Permalloy). Generally, these materials do not produce heads which have a high wear tolerance. As such, these heads will tend to wear out in a relatively short time. In addition, this class of materials have a low magnetic moment density (10 kGauss for NiFe), or saturation flux density, which limits their ability to record on very high coercivity media.
[0015] The second method also relies on plating for the top magnetic layer and is therefore limited to the same class of materials. In addition, the use of ion milling makes the fabrication of such a head overly complex. The photoresist pattern can be applied relatively precisely; thereby forming a channel over the gap. However, the traditional ion milling technique is rather imprecise and as the ions pass through that channel they are continuously being deflected. Conceptually, in any recording gap, so cut, the relative aspect ratios involved prevent a precise gap from being defined. In other words, this is a shadowing effect created by the photoresist and causes the gap in the magnetically permeable material to be angled. Generally, the sidewalls of the gap will range between 45°-60°from horizontal. This introduces a variance into the magnetic flux as it exits the gap, resulting in a less precise timing based pattern being recorded onto the servo track.
[0016] Therefore, there exists a need to provide a magnetic recording head capable of producing a precise timing based pattern. Furthermore, it would be advantageous to produce such a head having a tape bearing surface which is magnetically efficient as well as wear resistant and hence a choice of sputtered rather than plated materials are required. Thus, it is proposed to use a fully dry process to fabricate a time based head using predominantly iron nitride based alloys.
SUMMARY OF THE INVENTION
[0017] The present invention relates to a method of fabricating a magnetic recording head, and more particularly a recording head for producing a time based servo pattern.
[0018] A substrate consisting of a ceramic member, glass bonded between a pair of ferrite blocks is prepared. The substrate is then cleaned, polished and if desired, ground to a particular curvature. On top of this substrate, a magnetically permeable thin film is deposited, preferably by a sputtering process. The thin film is selected from a class of materials having a high wear tolerance as well as a high magnetic moment density, such as FeN. The alloys in this class of materials need to be sputtered onto the substrate, as other thin film deposition techniques, such as plating, are incompatible with these materials.
[0019] Once the thin film is present, the substrate is placed within the path of a focused ion beam (FIB) orthogonally oriented to the major surface of the thin film. The FIB is used to mill a complex patterned gap though the thin film layer. This gap is extremely precise and will allow the recording head to accurately produce a similar pattern on magnetic tape.
[0020] The FIB must be controlled to only mill the patterned gap and no other portion of the thin film. To define these parameters within the FIB control system, several techniques are available. In general, a non-destructive pattern is applied to the surface of the thin film. A graphical interface within the FIB control system allows the operator to visually align the pattern with the FIB milling path. One way to accomplish this is to apply a very thin layer of photoresist to the thin film. A mask is then employed to create the very precise gap pattern. Because photoresist is visually distinct from the remainder of the substrate, the FIB can be aligned with this pattern. As opposed to the usual thick film photoresist used in traditional ion milling as a protective layer (or selectively etched layer), the photoresist in the present invention will serve no other purpose in the milling process. Alternatively, numerical coordinates, representing the gap to be cut, can be directly entered into the FIB control system.
[0021] Once the gap or gaps have been cut into the thin film, the substrate is coupled with a coil to produce a functional recording head.
[0022] It is an object of the present invention to provide a method of making a magnetic recording head having a precisely defined gap structure.
[0023] It is another object of the present invention to produce a magnetic recording head utilizing a focused ion beam to define the gap and track width structure.
[0024] It is still another object of the present invention to simultaneously define and create all three dimensions of a gap structure in a magnetic head.
[0025] It is yet still another object of the present invention to fabricate a magnetic recording head wherein the gap depth is determined primarily by the thickness of the deposited thin film.
[0026] It is yet another object of the invention to use a focused ion beam to produce a thin film magnetic recording head employing a timing based servo pattern.
[0027] It is yet still another object of the present invention to produce a thin film magnetic recording head having a highly wear resistant tape bearing surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] [0028]FIG. 1 is a side planar view of a substrate bearing a magnetic thin film.
[0029] [0029]FIG. 2 is a top planar view of the substrate shown in FIG. 1.
[0030] [0030]FIG. 3 is top planar view of a portion of thin film, bearing indicia of a gap to be milled.
[0031] [0031]FIG. 4 is a schematic diagram of a FIB milling a gap into a thin film.
[0032] [0032]FIG. 5 is a top planar view of a thin film having gaps milled by a FIB.
[0033] [0033]FIG. 6 is a side sectional view taken about line VI-VI.
[0034] [0034]FIG. 7 is a top planar view of a thin film having gaps milled by a FIB.
[0035] [0035]FIG. 8 is side sectional view taken about line VII-VII.
[0036] [0036]FIG. 9 is a top planar view of a portion of thin film having a gap and endpoints milled by a FIB.
[0037] [0037]FIG. 10 is a top planar view of a substrate bearing gaps and air bleed slots.
[0038] [0038]FIG. 11 is an end planar view of a substrate bearing air bleed slots.
[0039] [0039]FIG. 12 is a side planar view of a magnetic recording head.
[0040] [0040]FIG. 13 is an end planar view of a magnetic recording head.
[0041] [0041]FIG. 14 is a partial perspective view of thin film layer bearing a set of time based or angled recording gap pairs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] The present invention is a method of making a thin film magnetic recording head using a focused ion beam (FIB) to mill out gaps in the tape bearing surface. Referring to FIG. 1, a substrate 10 is created by glass bonding two C-shaped ferrite blocks 12 to a medially disposed ceramic member 14 . The sizes and relative proportions of the ferrite blocks 12 and ceramic member 14 may vary as dictated by the desired parameters of the completed recording head. Furthermore, the choice of materials may also vary so long as blocks 12 remain magnetic while member 14 remains magnetically impermeable.
[0043] A layer of magnetically permeable material is deposited as a thin film 16 across an upper surface of each of the ferrite blocks 12 , as well as the upper surface of the ceramic member 14 . The magnetically permeable thin film 16 will become the tape bearing and data writing surface for the magnetic head 5 (see FIGS. 12 & 13). As such, it is desirable to form the layer of thin film 16 from a material which has a relatively high magnetic moment density (greater or equal to about 15 kGauss) and is also wear resistant. An exemplary material for this purpose is FeN or alternatively Sendust™. For example, FeN has a magnetic moment density on the order of 19 to 20 kGauss and is resistant to the frictional deterioration caused by continuous tape engagement. Any of the alloys in the iron nitride family, such as iron aluminum nitride, iron tantalum nitride, etc., and including any number of elements, are also ideally suited. FeXN denotes the members of this family, wherein X is a single element or a combination of elements, as is known in the art.
[0044] FeXN is created by sputtering a FeX alloy (or simply Fe) in a nitrogen rich environment. It is not available in quantities sufficient for plating. Furthermore, even if so available, the FeXN would decompose during the electrolytic plating process. This is in stark contrast to the simple alloys which may be readily utilized in electrolytic plating techniques. Therefore, while it is advantageous to use alloys, such as FeXN, magnetic recording heads cannot be formed with them, in any previously known plating process. In addition, the most desirable alloys to use are often composed of three of more elements. Plating is generally limited to the so called binary alloys, and as explained above is not conducive to binary gaseous alloys, such as FeN. The use of sputtering in combination with the use of a FIB, not only allows any of these materials to be used but also produces a better wearing magnetic thin film with a higher saturation flux density and of sufficient permeability for use as a servo write head.
[0045] Referring again to FIG. 1, the thin film 16 is sputtered onto the surface of the ferrite blocks 12 and the ceramic member 14 . Prior to the sputtering process, the surface is polished and prepared in a manner known to those skilled in the art. If desired, the surface may be ground to produce a slight curvature. This curvature will facilitate smooth contact between the tape and the completed head 5 as the tape moves across the tape bearing surface.
[0046] The thickness of the deposited thin film 16 determines the efficiency of the magnetic head and also its predicted wear life. The thicker the tape bearing surface (thin film 16 ) is, the longer the head will last. Conversely, the thicker the magnetic film, the longer it will take to process or etch with a FIB and it will also process less precisely. Therefore, the thin film should be deposited in a thickness of about 1 to 5 μm. Ideally, the thickness will be about 2 to 3 μm.
[0047] [0047]FIG. 2 is a top view of the substrate 10 and in particular the major surface of magnetic thin film 16 with the underlying ceramic member 14 shown in dashed lines. The area 18 is defined by the upper surface of the ceramic member 14 (the magnetic sub-gap) and is where the appropriate gaps will eventually be milled.
[0048] Referring to FIG. 3, only area 18 is shown. Within area 18 , some indicia 20 of the eventual gap positions are laid down. It should be noted that two diamond shaped gaps are to be milled as shown in FIG. 3; however any shape and any number of gaps could be created. Indicia 20 is simply an indication of where the FIB is to mill. One way of accomplishing this is to place a layer of photoresist 22 down and define the indicia 20 with a mask. Using the known techniques of photolithography, a layer of photoresist 22 will remain in all of area 18 except in the thin diamond defined by indicia 20 . Alternatively, the photoresist area could be substantially smaller than area 18 , so long as it is sufficient to define indicia 20 . The photoresist differs in color and height from the thin film 16 and therefore produces the visually discernible pattern. This pattern is then registered with the FIB control system through a graphical interface; thus delineating where the FIB is to mill. The photoresist serves no other purpose, in this process, than to visually identify a pattern. As such, many alternatives are available. Any high resolution printing technique capable of marking (without abrading) the surface of the thin film 16 could be used. Alternatively, the pattern could be created completely within the FIB control system. That is, numerical coordinates controlling the path of the FIB and representing the pattern could be entered; thus, obviating the need for any visual indicia to be placed onto the magnetic thin film 16 . Finally, a visual pattern could be superimposed optically onto the FIB graphical image of the substrate 10 , thereby producing a visually definable region to mill without actually imprinting any indicia onto the substrate 10 .
[0049] In any of the above described ways, the FIB 24 is programmed to trace a predefined pattern, such as the diamond indicia 20 shown in FIG. 3. The FIB will be orientated in a plane orthogonal to the major surface of the thin film 16 .
[0050] [0050]FIG. 4 is a sectional view of FIG. 3, taken about line IV-IV and illustrates the milling process utilizing FIB 24 . The upper surface of the thin film 16 has been coated with a thin layer of photoresist 22 . The visual indicia 20 of the diamond pattern is present, due to the area of that indicia 20 being void of photoresist. The FIB 24 has already milled a portion of the pattern forming gap 30 . The FIB as shown has just begun to mill the right half of the pattern. The beam of ions 26 is precisely controlled by the predefined pattern which has been entered into the FIB's control system. As such, the beam 26 will raster back and forth within the area indicated by indicia 20 . The beam 26 will generally not contact a significant amount of the photoresist 22 and will create a gap 30 having vertical or nearly vertical side walls. The width of the ion beam is controllable and could be set to leave a predefined amount of space between the edge of the side wall and the edge of the indicia 20 . The FIB 24 will raster back and forth until all of the indicia 20 have been milled for that particular head.
[0051] After the FIB 24 has milled all of the gap(s) 30 , the photoresist 22 is washed away. Alternatively, any other indicia used would likewise be removed. FIG. 5 illustrates area 18 of substrate 10 after the photo resist 22 has been removed. Thin film 16 is exposed and has precisely defined gaps 30 milled through its entire depth, down to the ceramic member 14 . FIG. 6 is a sectional view of FIG. 5 taken about line VI-VI of FIG. 5 and illustrates the milled surface of gap 30 . The gap 30 is precisely defined, having vertical or nearly vertical walls.
[0052] Referring to FIG. 14, a partial perspective view of a time based recording head 5 is shown. The major surface 50 of thin film 16 lies in a plane defined by width W, length L, and depth D. D is the deposited thickness of the magnetic film 16 . The FIB will always mill through thin film 16 through a plane perpendicular to the major surface 50 which would also be parallel to depth D. By conventional standards, the gap 30 will have a magnetic gap depth equal to depth D and a gap width equal to width W and a gap length (L′)equal to the span of gap 30 .
[0053] The upper surface of thin film 16 , shown in FIG. 7, represents one of many alternative time based patterns which may be created using a FIB 24 . Here, gaps 30 will be milled in exactly the same fashion as described above, except that indicia 20 , when utilized, would have formed the pattern shown in FIG. 7. FIG. 8 is a sectional view taken about line VII-VII of FIG. 7 and shows how gap 30 continues to have precisely defined vertical sidewalls. Furthermore, the upper horizontal surface 32 of ceramic member 14 is also precisely defined.
[0054] [0054]FIG. 9 illustrates yet another pattern which may be defined using FIB 24 . Here, gap 30 is in the shape of an augmented diamond. Rather than defining a diamond having connected corners, gap 30 is milled to have termination cells or endpoints 34 , 35 , 36 and 37 . Creating endpoints 34 , 35 , 36 and 37 increases the definition of the finished recorded pattern near the ends of the track.
[0055] The next step in the fabrication process is to create air bleed slots 40 in the tape bearing surface of the substrate 10 , as shown in FIG. 10. Once substrate 10 has been fabricated into a recording head, magnetic tape will move across its upper surface in a transducing direction, as shown by Arrow B. Therefore, the air bleed slots 40 are cut perpendicular to the transducing direction. As the tape moves over the recording head at relatively high speed, air entrainment occurs. That is, air is trapped between the lower surface of the tape and the upper surface of the recording head. This results from the magnetic tape, comprised of magnetic particles affixed to a substrate, being substantially non-planar on a microscopic level. As the tape moves over the recording head, the first air bleed slot encountered serves to skive off the trapped air. The second and subsequent slots continue this effect, thus serving to allow the tape to closely contact the recording head. As the tape passes over the recording gap(s) 30 , it is also held in place by the other negative pressure slot 42 , 43 encountered on the opposite side of the gap(s) 30 . Therefore, there is a negative pressure slot 42 , 43 located on each side of the recording gap(s) 30 .
[0056] [0056]FIG. 11 is a side view of the substrate 10 , as shown in FIG. 10. The upper surface of the substrate 10 has a slight curvature or contour. This acts in concert with the air bleed slots to help maintain contact with the magnetic tape. The air bleed slots 40 are cut into the substrate 10 with a precise circular saw, as is known by those skilled in the art. The air bleed slots 40 are cut through thin film 16 , which is present but not visible in FIG. 11. Alternatively, the air bleed slots 40 could be cut prior to the thin film 16 having been deposited.
[0057] Substrate 10 has been longitudinally cut, thus removing a substantial portion of the coupled C-shaped ferrite blocks 12 and ceramic member 14 . This is an optional step which results in an easier integration of the coils and ferrite blocks. FIG. 13 illustrate how a backing block 46 is bonded to substrate 10 . The backing block 46 is composed of ferrite or another suitable magnetic material. Wiring is wrapped about the backing block 46 thus forming an electrical coil 48 . With this step, the fabrication process has been completed and a magnetic recording head 5 has been produced.
[0058] In operation, magnetic recording head 5 is secured to an appropriate head mount. Magnetic tape is caused to move over and in contact with the tape bearing surface of the head 5 , which happens to be the thin film layer 16 . At the appropriate periodic interval, electrical current is caused to flow through the coil 48 . As a result, magnetic flux is caused to flow (clockwise or counterclockwise in FIG. 13) through the back block 46 , through the ferrite blocks 12 , and through the magnetic thin film 16 (as the ceramic member 14 minimizes a direct flow from one ferrite block 12 to the other causing the magnetic flux to shunt through the permeable magnetic film). As the magnetic flux travels through the magnetic thin film 16 , it leaks out through the patterned gaps 30 , thus causing magnetic transitions to occur on the surface of the magnetic tape, in the same pattern and configuration as the gap 30 itself.
[0059] Referring to FIGS. 10 and 12, it can be seen that the width of the head 5 (or substrate 10 ) is substantially larger than a single patterned gap 30 . This allows the recording head to bear a plurality of patterned gaps 30 . For example, FIG. 10 illustrate a substrate 10 having five recording gaps 30 which could then write five servo tracks simultaneously. More or less can be utilized as desired and the final size of the head 5 can be adjusted to whatever parameters are required.
[0060] Rather than cutting the substrate 10 as shown in FIG. 11 and applying a coil as shown in FIG. 13, the substrate 10 could remain whole and the coils could be added to the C-shaped ferrite blocks 12 , as they are shown in FIG. 1.
[0061] The above head fabrication process has been described with respect to a magnetic recording head employing a timing based servo patter. However, the process could be applied equally well to any type of thin film recording head. That is, those of ordinary skill in the art will appreciate that the FIB milling of the gaps could accommodate any shape or pattern, including the traditional single gap used in half-track servo tracks.
[0062] Those skilled in the art will further appreciate that the present invention may be embodied in other specific forms without departing from the spirit or central attributes thereof. In that the foregoing description of the present invention discloses only exemplary embodiments thereof, it is to be understood that other variations are contemplated as being within the scope of the present invention. Accordingly, the present invention is not limited in the particular embodiments which have been described in detail therein. Rather, reference should be made to the appended claims as indicative of the scope and content of the present invention. | A thin film magnetic recording head utilizing a timing based servo pattern is fabricated using a focused ion beam (FIB). The recording head is fabricated by sputtering a magnetically permeable thin film onto a substrate. A gap pattern, preferably a timing based pattern, is defined on the thin film and the FIB cuts a gap through the thin film based on that pattern. Once completed, the recording head is used to write a servo track onto magnetic tape. The timing based servo track then allows for the precise alignment of data read heads based on the positional information obtained by a servo read head which scans the continuously variable servo track. | 8 |
This application claims the priority of U.S. Provisional Patent Application Ser. No. 60/700,555 filed Jul. 19, 2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to devices and methods for conducting liner drilling and subsequent completion of the drilled section by securing the liner into place by anchoring and cementing.
2. Description of the Related Art
In its basic form, a wellbore is drilled using a drill bit that is attached to a drill string fashioned of drill pipe. When the wellbore is drilled to an original desired depth, the drill string and bit are removed from the hole. Then steel casing is inserted into the borehole and cemented in place as a protective tubular sheath to prevent collapse of the borehole wall. The term “casing,” as used herein will refer to those protective sheaths that extend along a portion of the wellbore all the way to the surface. The well can then be drilled to deeper depths in successively smaller diameter intervals below the original depth. These lower intervals are then lined with wellbore liners. As used herein, the term “liner” will refer to those protective sheaths that extend along a portion of the wellbore, but do not extend all the way to the surface.
In addition to traditional drilling using drill strings made up of drill pipe, techniques have been developed recently for casing drilling and liner drilling. In casing drilling, the bottom hole assembly containing the drill bit is threaded to a section of casing and, after drilling, the casing is hung at the top of the wellbore. Liner drilling is a similar concept. In liner drilling, the liner to be cemented in serves as a part of the drilling string while traditional drill pipe usually forms the upper part of the drill string. The bit can be attached to the liner and the liner then rotated within the borehole. Alternatively, a mud motor is attached to liner and the mud motor is used to turn the bit while the liner remains stationary. When liner drilling is completed, the drill pipe portion of the drill string is detached from the liner and withdrawn from the wellbore. The liner portion of the drilling string remains in the borehole, set on the bottom of the hole and is later cemented into place. The bit and mud motor are also left in the hole.
A significant problem with this conventional liner drilling process is that the liner can deform by bending or corkscrewing under its own weight when set down on bottom. This is especially true of very long liners. If the liner is cemented in this condition, it will be permanently deformed and perhaps be unusable for passing large diameter tools through. For this reason, a number of “one-trip” liner drilling arrangements have been developed that incorporate liner hangers into the drilling string on the upper end of the liner so that the liner can be anchored to the pre-existing casing after cementing. An example of a “one-trip” liner drilling system is described in U.S. Pat. No. 5,497,840, issued to Hudson.
A major problem with “one trip” liner drilling systems is their ability to return drill cuttings to the surface of the wellbore. The liner portion of the drill string has a much greater diameter than traditional drill pipe. As a result, the annulus surrounding the liner portion is quite small, leaving little room for pumped down drilling mud and generated cuttings to return to the surface of the well. While this problem is inherent to the process of liner drilling, it is made substantially worse by the presence of any exterior components that extend outwardly into the annulus beyond the diameter of the liner. Thus, externally mounted hangers or packers, that might be used to hang the liner in tension from the casing or liner above could not be run in with the liner during the drilling operation without destroying the ability to drill and remove cuttings effectively during drilling. Thus, there is a need to be able to conduct liner drilling with minimal exterior components to allow annular bypass of returning drilling mud and cuttings.
The present invention addresses the problems of the prior art.
SUMMARY OF THE INVENTION
The invention provides improved methods and systems for conducting liner drilling and subsequent completion of the drilled section by cementing and anchoring the liner into place. The methods and systems of the present invention prevent the liner from being cemented in in a bent or corkscrewed configuration. Additionally, the systems and methods of the present invention minimize the number of exterior components associated with the liner during drilling so as to allow relatively unrestricted return of drilling mud and cuttings.
In accordance with preferred embodiments of the invention, a liner is drilled into a wellbore below original depth using a running tool. A liner setting sleeve having a substantially smooth exterior is affixed to the top of the liner, thereby permitting substantially unrestricted annular bypass and minimal exterior mechanical complexity during drilling. Once the target depth has been reached, the liner is set on the bottom of the hole and the liner setting tool is released from the liner. The running string is then withdrawn from the hole. Next, a liner hanger/packer assembly is run into the hole. The liner hanger/packer assembly has a latch-in seal assembly to latch into the liner setting sleeve. Once, latched, the liner is lifted off the bottom of the hole. A liner packer is then set to hang the liner in tension. Thereafter, the liner may be anchored to the casing above and cemented into place within the wellbore in a substantially straight and true condition.
BRIEF DESCRIPTION OF THE DRAWINGS
For a thorough understanding of the present invention, reference is made to the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, wherein like reference numerals designate like or similar elements throughout the several figures of the drawings and wherein:
FIG. 1 is a schematic side, cross-sectional view of an exemplary borehole being drilled from the original depth to a lower interval using liner drilling.
FIG. 2 is a schematic side, cross-sectional view of the borehole shown in FIG. 1 now with the running tool being removed.
FIG. 3 is a schematic side, cross-sectional view of the borehole of FIGS. 1 and 2 now with a liner hanger/packer assembly being latched into the liner setting sleeve.
FIG. 4 is a schematic side, cross-sectional view of the borehole of FIGS. 1-3 now with the liner being picked up off the bottom of the borehole.
FIG. 5 depicts the setting of a liner packer to hang the liner in tension.
FIG. 6 depicts a cementing operation to secure the liner in place.
FIG. 7 is an enlarged, cross-sectional side view of the liner setting sleeve.
FIG. 8 is an enlarged, cross-sectional side view depicting the running tool attached to the liner setting sleeve.
FIG. 9 is an enlarged, partial cross-sectional side view showing the liner hanger/packer latched into the liner setting sleeve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 depicts an exemplary wellbore 10 that has been drilled from the surface 12 through the earth 14 to an original depth 16 . Metallic casing 18 has been cemented in the wellbore 10 from the surface 12 down near the original depth 16 . A liner drilling system 20 has been inserted into the wellbore 10 from a drilling rig 22 at the surface 12 . In FIG. 1 , the liner drilling system 20 is drilling a deeper interval portion 24 of the wellbore 10 . The liner drilling system 20 includes a bottom hole assembly 26 with a drill bit 28 thereupon. The bottom hole assembly 26 is attached by a landing collar 30 to a section of liner 32 . The liner section 32 is of a length that approximates the length of the deeper interval portion 24 to be drilled. Secured to the upper end of the liner section 32 is a liner setting sleeve 34 . The liner setting sleeve 34 is shown in greater detail in FIG. 7 . It is noted that the liner setting sleeve 34 has a smooth external radial surface 36 and is affixed by a threaded connection 38 to the upper end of the liner section 32 . It is noted that, although the liner setting sleeve 34 is depicted as having a greater outer diameter than the liner 32 , the diametrical increase is, in actuality, very small, and presents no obstacle to the passage of drilling mud and cuttings. The liner setting sleeve 34 defines a latching groove 39 within. A suitable liner setting sleeve is the HRD™ Liner Setting Sleeve, which is available commercially from Baker Oil Tools of Houston, Tex. A short PBR (polished bore receptacle) 40 is secured to the upper end of the liner setting sleeve 34 .
The liner drilling system 20 also includes a length of running string formed of drill pipe 42 that extends downwardly from the drilling rig 22 and is secured to the liner setting sleeve 34 and PBR 40 at its lower end. FIG. 8 illustrates an exemplary releasable interconnection between the drill pipe running string 42 and the liner section 32 . A packoff 44 is disposed within the PBR 40 to secure the two components together. A hydraulic releasing tool 46 is also disposed within the PBR 40 and setting sleeve 34 . Suitable commercially available devices for use as the packoff 44 , setting sleeve 34 , and hydraulic releasing tool 46 are those within a standard HRD™ Hydraulic Release Setting Tool, which is available commercially from Baker Oil Tools of Houston, Tex. With further reference to FIG. 8 , it is noted that the drill pipe running string 42 defines a central flowbore 48 for passage of drilling mud downwardly to the drill bit 28 . During drilling, drilling mud is pumped downwardly through the central flowbore 48 and drilling mud and drill cuttings are circulated upwardly through the annulus 50 to the surface 12 . Because there are no external packers or hangers on the drilling system 20 , the cuttings and mud have a substantially unrestricted return path through the annulus 50 .
FIG. 2 shows the wellbore 10 now drilled to the deeper interval portion 24 . The drill pipe running string 42 has been released from the liner portion 32 by actuation of the hydraulic releasing tool 46 and is being removed from the wellbore 10 . At this point, the liner portion 32 , bottom hole assembly 26 and bit 28 are resting on the bottom 52 of the drilled deeper interval portion 24 of the wellbore 10 . The liner portion 32 may become deformed in this condition by bending, buckling, or corkscrewing.
FIG. 3 illustrates the next step in the liner drilling process wherein a latching liner hanger assembly 54 is run into the wellbore 10 on a drill pipe running string 55 to be secured to the upper end of the liner portion 32 by latching engagement. FIG. 9 illustrates the latching arrangement and the latching liner hanger assembly 54 in greater detail. The latching liner hanger assembly 54 includes a liner packer 56 having an elastomeric sealing element 58 that is set by axial movement upon ramped surface 60 . The packer 56 is preferably actuated hydraulically, in a manner that is known in the art. The hanger assembly 54 also includes a set of anchoring slips 62 that are moveable radially outwardly to form a biting engagement with a surrounding tubular member. The slips 62 , like the packer 56 , are preferably hydraulically actuated. In addition, the hanger assembly 54 includes a latching sub 64 at its lower end. The latching sub 64 includes a set of collets 66 with radially outward projections 68 that are shaped and sized to reside within the groove 39 of the liner setting sleeve 34 .
FIG. 4 shows the subsequent step of lifting the liner 32 off the bottom 52 so that the liner 32 is hanging in tension. Because the liner 32 is hanging in tension, the deformations from corkscrewing or bending are undone. At this point, the hanger assembly 54 is actuated to urge the slips 62 and sealing element 58 of the packer 56 radially outwardly and into engagement with the casing 18 . This ties the liner 32 in with the casing 18 above. In FIG. 5 , the liner packer 56 and slips 62 are now in the set position.
FIG. 6 illustrates the step of cementing in the liner 32 . Conventional cementing techniques are used to circulate cement down through the flowbore of the drill pipe running tool 55 , as depicted by arrows 70 . The cement then passes through the liner 32 and the bit 28 to be deposited at the bottom 52 of the wellbore 10 . From there, placed cement 72 will rise to fill in the annular space 74 between the liner 32 and the sidewalls of the extended length portion 24 of wellbore 10 . The interior of the drill string running tool 55 and the liner 32 are then cleaned using wiper darts of a type known in the art. As the techniques of cementing in liners are well known to those of skill in the art, they will not be described in further detail herein.
After the completion of cementing, the drill string running tool 55 is then removed from the latching liner hanger assembly 54 . This is usually accomplished by rotating the drill string running tool 55 to unthread the hanger assembly 54 and then withdrawing the running tool 55 from the wellbore 10 .
Those of skill in the art will recognize that the methods and systems of the present invention provide a number of advantages over conventional liner drilling and placing systems. First, they help ensure that the liner 32 will not be deformed from compression bending or corkscrewing at the time that it is cemented in or anchored to the casing 18 . As a result, there will be fewer subsequent problems with running large diameter tools through the liner 32 at a later point in development of the wellbore 10 . Additionally, the liner drilling process is made more effective because there is a minimum complication of the annulus 50 during the drilling phase. There are no external packers or slips associated with the liner 32 during the drilling phase, and therefore, the cuttings and mud can more easily reach the surface 12 .
Those of skill in the art will recognize that numerous modifications and changes may be made to the exemplary designs and embodiments described herein and that the invention is limited only by the claims that follow and any equivalents thereof. | Methods and systems for conducting liner drilling and subsequent completion of the drilled section by cementing and anchoring the liner into place. The methods and systems prevent the liner from being cemented in in a bent or corkscrewed configuration. Additionally, there are no exterior components associated with the liner during drilling so as to allow relatively unrestricted return of drilling mud and cuttings. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the priority of European Patent Application, Serial No. 15179086.2, filed Jul. 30, 2015, pursuant to 35 U.S.C. 119(a)-(d), the disclosure of which is incorporated herein by reference in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a system and a method for control and/or analytics of an industrial process and more particularly to a system and a method for prioritization of transmission of process data from plant-side automation and/or processing units to processing units external to the plant.
[0003] The following discussion of related art is provided to assist the reader in understanding the advantages of the invention, and is not to be construed as an admission that this related art is prior art to this invention.
[0004] A plurality of plants that undertake process control generally fulfill simple automation and closed-loop control technology tasks. Commonly these tasks are carried out by automation units that are installed on site and thus in the vicinity of the process to be automated. Often such plants have a plurality of smaller automation units, oftentimes also spatially separated from one another, which then results in the individual process tasks also running in a distributed manner. Because of their restricted computing power, such smaller automation units tend not to be capable of mapping complex closed-loop control structures or closed-loop control and/or simulation strategies, as are possible in the higher classes of automation device. Such more complex closed-loop control strategies, which can require a significant computing capacity, can for example be so-called Model Predictive Controls (MPC), as are preferably employed in process engineering processes. Frequently the desire is also to set up complex closed-loop controls that are based on comprehensive historical data, and to use these for example in so-called Support Vector Machines (SVM), in order to be able to make optimizations to the process on this basis. Therefore such processing-intensive process engineering processes or data analysis models are frequently automated in the superordinate control and monitoring system of the plant.
[0005] We are currently experiencing a trend in the direction of central data analytics in external processing units (so-called cloud based analytics). With these external processing units cloud-based process controls for an industrial plant, the process data is collected from a plant in order to then provide it to an external processing unit for analysis. The analysis result is returned to the plant for improving the process control and process optimization. Because of its comprehensive analytics methods and the mostly self-learning techniques, cloud-based analytics allows a significant enhancement of the process controls. However the cloud-processing approaches are often not real-time-capable, because large amounts of data must be transferred from sensors or actuators of the industrial process or internally-formed data from the plant into the external processing unit, in order to analyze it there. Thereafter the analytics result is to be returned for further actions in order for it to become effective for the processes in the plant, which overall means unacceptable time delays. Closed-loop control circuits—especially when, because of the closed-loop control speed, comparatively fast sampling rates become necessary—are problematic with cloud-based methods on account of the uncertain but at least slightly deterministic communication delays. The major sources of such time delays lie a) in the data acquisition, the pre-processing and the compression, b) in the transmission of data into the cloud and c) in the analytics and result computation itself. To ameliorate the problem of latency times in cloud-based systems, attempts are being made to make data collection possible by suitable faster hardware. Furthermore it is proposed that the data undergoes processing in order for only a reduced amount of data then to be transmitted into the cloud-based system. A further point in the approach relates to the transmission of the data, in that attempts are being made to provide faster transmission channels with corresponding bandwidths. As part of the analytics itself the cloud-based systems are equipped with high-end computers running efficient algorithms.
[0006] It has been shown that high bandwidths and low wait times alone are often not sufficient. This is especially true when critical industrial processes and large amounts of data to be transmitted are involved.
[0007] It would therefore be desirable and advantageous to specify an alternate facility and an alternate method to obviate prior art shortcomings and to reduce latency times of support cloud-based process control and/or analytics deterministically in real time in the industrial environment and systematically.
SUMMARY OF THE INVENTION
[0008] According to one aspect of the present invention, a system for controlling an industrial process includes at least one automation or processing unit on the plant side. The industrial plant can be any plant with a production or fabrication process in the industrial environment. Plant-side means that the automation unit is a component of the local automation system and commonly is arranged close to the process. The automation unit carries out a number of first process variable computations. To this end the automation unit is linked into the process via sensors and actuators. Process input variables are the sensors and actuators, which, for the control of the process, are periodically inputted in and buffered by the input module of the automation unit and are thus available for further processing by the processors of the automation components. The actual processing within the automation unit is carried out in accordance with a process control algorithm. The output variables of this processing, i.e. the results of the process control algorithm of the plant-side automation unit generally become periodically effective for the process via an output module of the automation unit.
[0009] The plant-side processing unit can however also be an MES (Manufacturing Execution System) or ERP (Enterprise Resource Planning) system. Such MES or ERP systems possess a wide scope of functions, wherein their functions are based on the widest variety of process data and process variable computations. The intermediate data present in these systems that is to undergo further processing falls within the meaning of the term first process variable computations as used herein.
[0010] While the process variable computations of the automation units generally have a direct effect on the industrial process (for example by pre-specifying target values for a closed-loop controller) the process variable computations of MES or ERP systems tend to act indirectly on the industrial process, in that the MES is responsible for the scheduling of production processes, for example by determining the production plan by collection of orders or in that an MES carries out check and management of resources, in order to prepare for production or to carry out production ordering of the necessary material resources and/or informing another system about the progress of the production process. Or the process is acted on indirectly by the exchange of process data, status analysis of operational device situations, material usage information or historical or current process data.
[0011] The system also has at least one processing unit external to the plant, which carries out process variable computations and for this purpose receives local data from the plant-side automation or processing unit via a data link. The data link is realized via known communication mechanisms and standardized interfaces. The communication standards OPC (OPC DA, OPC UA) or TCP/IP (Profinet) belong to the communication mechanisms for example, which allow independent processing units to be interconnected into a distributed system. The standard interfaces include RPC, OLEDDB or SQL by way of example. A processing unit is to be seen as external to the plant if it is located spatially and/or functionally outside the local automation system. Such processing units external to the plant can be located at external service providers for example and are also referred to as cloud processing units.
[0012] The processing unit external to the plant carries out second process variable computations in parallel to or in addition to the computation of the first process variable computations of the plant-side automation or processing unit. In general these second process variable computations will be significantly more complex and require significantly greater computing power by comparison with the computing power within the local automation or processing unit. The more complex, second process variable computations in such cases will commonly be based on a larger volume of data. Where this data can be provided by the process itself (for example by additional and as yet unused sensors or actuators), said data is likewise read in and provided via the input element of the plant-side automation unit. Such data can however also include historical data or intermediate data, as is present for example within the plant-side automation or processing unit itself. The computations that are carried out in the processing unit external to the plant are far more complex and processor-intensive than those that can be carried out in the plant-side automation unit. Thus the external processing unit takes on expanded process engineering functions, as are known from MPC controls for example. Furthermore Condition Monitoring Systems, simulation systems or historical data based systems within this external processing unit can also carry out additional evaluations and for these purposes will also refer back to signals processed by the closed-loop controls. Because of the greater volume of data, especially historical data, the process control algorithms can for example also include so-called Support Vector Machine (SVM)-based Model Predictive Control (MPC) algorithms.
[0013] At least one data collector unit is disposed on the plant-side, wherein the data collector unit prioritizes the data transfer over the data link between the at least one automation or processing plant-side unit and the remote processing unit, external to the plant. The data collector unit is based on the underlying knowledge that, depending on the tasks of the remote processing unit, the local data does not have to be transmitted to the remote processing unit with equal priority. While different analytics or process management are addressed within the remote processing unit presents different demands in terms of data supply, the processes can be executed in parallel. On the other hand, certain tasks should be executed, especially deterministically repeatable, in real time while other tasks can be executed as subordinate task.
[0014] In an embodiment of the invention the data collector unit has a data buffer for buffering the local data. The data buffer stores all local data to be communicated to the remote processing unit and thus makes it available for prioritization.
[0015] As well as the data buffer, the data collector can also contain an element for pre-processing the local data. In this way for example a pre-compression of the data may be carried out.
[0016] According to a further aspect of the invention the data collector unit has a priority dispatcher and priority memories. The task of the priority dispatcher in these embodiments is to assign the local data to different priority memories, i.e. physically relocate local data into these priority memories. Alternatively, a prioritization within the data buffer is also possible by issuing of a priority flag for example. The local data is prioritized as a function of the requirements for its transmission time to the remote processing unit. The priority dispatcher has knowledge about which item of local data is relatively more important than another item of local data. The priority dispatcher obtains the information about this for example from the data record relating to the data item itself or via a categorization of data in respect of its use. For example for local data that is used for the comparatively fast closed-loop control algorithms, a higher-quality categorization can be stored than for data that is to be used for condition monitoring for example. In this way data is divided into different buffer areas and data with the highest priority level may be transmitted, as intended. Conversely the data with the lowest priority might not be transmitted at all, namely when the transmission becomes irrelevant as a result of the transmission of the higher-priority data. The priority memory with the highest priority is first transmitted to the remote processing unit, only when said data has been completely transmitted will the data of the priority memory with the next-lowest priority be transmitted etc. In the event of new data being loaded again from the data buffer into one or more higher-priority priority memories, the transmission of the data from the priority memory with lower priority is stopped and the data from the higher-priority memories will be transmitted, wherein transmission starts with the highest-priority memory content. Only after transmission of the higher priority memory content completes will the previously stopped transmission be started again. The priority memory can be realized in the form of a FIFO (first in first out) memory or in the form of a cyclic memory.
[0017] The priority memory can be dynamically configured by the priority dispatcher. i.e. the priority dispatcher can dynamically define the number of priority memories and can insure in this way that a sensible prioritization of the data transmission takes place. The priority dispatcher can allocate priority memory or release priority memory not needed.
[0018] In accordance with a further aspect of the invention the data collector unit has a monitoring module for the transmission speed of the communication connection to the remote processing unit, external to the plant. Advantageously it can be determined in this way whether the priority-controlled data transmission and the definition of the number of priority memories and the graduation of the different priority memories correlates with the volumes of data to be transmitted. For example a high transmission rate could reduce the number of priority memories and increase the jumps in priority between the different memories (graduation), while a lower transmission rate could increase the number and/or the granularity of priority memory graduation.
[0019] In one form of embodiment the monitoring module will update the priority dispatcher of the available transmission speed. In this way the latter can define the number and graduation of priority memories.
[0020] As an alternative or in addition the assignment of local data to the priority memories can also be undertaken on the basis of the available transmission speed. In this way for example data of an actually lower priority would be assigned to a priority memory of a higher order of priority when a comparatively higher transmission speed is available.
[0021] According to a further aspect the priority dispatcher is configurable such that it determines the transmission time requirement statically or dynamically. The transmission time requirement and subsequently the definition of the priority is determined from the significance of the local data to be transmitted. The priority of the data can depend on the application case of the analytics or of the process control. Thus for example data that contains the power consumption of a machine can be stored in a high-priority priority memory, while for example data about the vibration of the machine can be assigned in a memory of comparatively lower priority. Or it can be configured that process data of lower resolution and thus also lower data volume is stored in a high-priority memory, while process data with high resolution and thus also high data volume is stored in a memory with comparatively lower priority. In this way the system is advantageously capable of reacting to the data volume occurring?? and insuring that important data with low latency time requirement is processed in the remote processing unit and thus computation results from the processing unit external to the plant can promptly become effective for the process.
[0022] In an alternate form of embodiment the buffering of the data in the data buffer of the data collector unit can already be done by the priority dispatcher for example. Typically the collection of data in the data buffer is done on the basis of API (application programming interface) calls, which the actual data traffic then follows. These API calls can be made by the priority dispatcher. If data is classified as less relevant and thus of lower priority either dynamically during the runtime of the system or manually by an operator intervention, it can be insured that this data is not even buffered in the data buffer.
[0023] In an aspect of the invention there is provided a system for remotely controlling an industrial process in a plant, comprising at least one plant-side automation or processing unit disposed in the plant and acting on the industrial process, the plant side unit is capable of carrying out first process variable computations, and a remote processing unit, i.e. a processing unit disposed outside the plant, the remote unit capable of carrying out second process variable computations. The remote unit receives local data from the at least one plant-side unit via a data link. At least one data collector unit is disposed in the plant, the data collector unit prioritizes data transfer via the data link between the at least one plant-side unit and the remote unit.
[0024] The object is further achieved by a method for transmission of local data of an industrial process from at least one plant-side automation or processing unit disposed in the plant, to a remote processing unit, disposed externally to the plant by a plant-side data collector unit. The local data can be process data, historical data, intermediate data etc. A plant-side data collector unit is to be understood as a software-based data collector constructed from separate hardware or integrated as a software module into the at least one automation or processing unit. The data collector is linked for communication purposes to the at least one plant-side automation or processing unit. In a first step the method comprises collecting local data from the at least one plant-side automation or processing unit in a data buffer. In a subsequent step the locally buffered data is read out by a priority dispatcher and entered into priority memories of different orders of priority, wherein the entries are made as a function of the requirements for their transmission time to the remote processing unit. I.e. the priority dispatcher accepts the data from the data buffer and arranges it in one of the priority memories that have a different order of priority. A method step subsequent to this step sends the data stored in the priority memory of the first order of priority to the remote processing unit. The priority memory of the first order of priority in this case is the memory that contains the data of the highest priority. This guarantees that the high-priority industrial data is put into a high-priority buffer that is then transmitted with preference. The analytics element within the remote processing unit does not have to wait for the entire volume of data before it begins to analyze the data. Whenever results, even partial results, are available on the basis of the high-priority data, these are quickly sent back to the process, which leads to marked reduction of overall latency times in the system. The method is thus the basis for real time operations based on industrial data in cloud-based analytics applications.
[0025] In accordance with a further aspect of the invention, the data stored in the priority memory of order X where X is 2,3,4, . . . n is sent respectively after sending data stored in priority memories of smaller X, i.e. of higher priority. Stated differently after the data has been sent completely for the priority memory of order of priority 1 to the remote processing unit, the data of the priority memory of order 2 is sent and after all this data has been sent, the data of the priority memory of the order 3 and so forth.
[0026] The method can include the data from priority memories of a lower order not being sent, namely when it is recognized for example that not all local data may be transmitted to the remote processing unit within a defined time window. In this case the transmission of lower-priority data can be entirely dispensed with in favor of the higher-priority data and the corresponding memory can be cleared out.
[0027] According to an important aspect the sending of data from priority memories of the orders of priority X is stopped, where data has been entered in the interim into priority memories of orders of priority lower than X, i.e. having higher priority. In other words for example during the sending of data from the memory of the order 2 via the priority dispatcher, the priority memory of the order 1 is again being filled with one or more items of high-priority data, thus the sending of the data of the memory of order 2 is interrupted and the data of the memory of order 1 is sent.
[0028] In accordance with a further aspect the interruption of sending of data is ended, provided the data entered in the interim has been sent. i.e. after complete sending of data entered in the interim, the sending of the data of the memory of order of priority 2 is resumed. After this data has been sent, the data of the memory of order of priority 3 is sent and so forth. In this way it is insured that that the high-priority data is transmitted without delay or at least with little delay.
[0029] In an embodiment of the invention the priority memory is allocated dynamically by the priority dispatcher. The priority dispatcher is thus capable of defining the memory in accordance with the data volume and the distribution of the data in respect to its priority and thus the necessary transmission time.
[0030] When the data collector unit monitors the transmission speed of the data link to the remote processing unit and updates the priority dispatcher of the available transmission speed, then advantageously for example there can also be a dynamic allocation of the priority memory on the basis of the transmission speed. In this way the transmission behavior can be further optimized, while retaining the premise that the latency time is shortened.
[0031] As an alternative the priority dispatcher may undertake the entry of the buffered local data into the priority memories on the basis of the available transmission speed. I.e. with a higher transmission speed for example the number of higher-priority data that is assigned to the memory of the order of priority 1 can be higher, the decision criteria for a graduation of the priorities to be assigned could vary dynamically.
BRIEF DESCRIPTION OF THE DRAWING
[0032] Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
[0033] FIG. 1 shows a system for distributed process control of an industrial plant with central data collector unit; and
[0034] FIG. 2 shows the schematic diagram of the data collector unit.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] Throughout all the figures, same or corresponding elements may generally be indicated by same reference numerals. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way. It should also be understood that the figures are not necessarily to scale and that the embodiments may be illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
[0036] Turning now to the drawing, and in particular to FIG. 1 , there is shown a system, generally designated by reference numeral 100 , for control of the industrial process 1 , for example a process for water treatment in a water clarification plant or any given production process in the industry. The industrial process can be a process which runs within one location, but also across a number of sites. The process 1 is controlled and regulated via decentralized, plant-side automation units 2 . These are equipped with one or more processors not shown here, which in collaboration with the necessary buffers, process the instructions stored in software code. The instructions may relate to all process control algorithms for open-loop control and closed-loop control of the process and also to data communication between the units. The automation units 2 , for open-loop control and closed-loop control of the process, have a series of effective connections 3 to sensors or actuators not shown in FIG. 1 . Via this connection the input element 17 reads in the data, which is then available in a memory area of the automation unit. Via the effective connections 4 , control commands are realized from output element 18 to actuators of the process not shown in FIG. 1 . Two automation units 2 are shown by way of example, however in practice any number of automation units will control, regulate and monitor the process. The automation units 2 are connected to the monitoring system 5 , which takes over the control and monitoring of the process 1 via a data link 20 . The monitoring system 5 maintains a data link 21 to the Manufacturing Execution System 6 , which for its part maintains a data link 22 to an Enterprise Resource Planning System 7 . On the basis of the local data generated via effective connection 3 , the automation units 2 execute process control algorithms 8 . These are monitoring analyses and closed-loop control functions effective for the process, which generally contain simpler and less complex analysis and closed-loop control tasks. The results of these process control algorithms are retained as process variable computation 19 in the automation unit 2 for further use and, where they are not needed, are overwritten in a subsequent cycle. The process variable computations 19 are however likewise influenced by computations within the superordinate systems 5 , 6 , 7 . Thus for example planning specifications based on customer orders or supplies of materials from MES and ERP system can mean that specific manufacturing processes are to be executed more slowly, in a more energy-optimized manner or more quickly. The SCADA can for example, because of disruptions at another point in the production process (for example the packaging department) likewise influence the upstream production process (for example the filling).
[0037] In this configuration the system 100 is operational and can fulfill its control, regulation and monitoring tasks.
[0038] The system 100 is expanded by a remote processing unit external to the plant 9 . This unit is equipped with one or more processors not shown here, which in collaboration with the necessary buffers, process instructions held in software code. The instructions relate to all process control algorithms for control, regulation and analytics of the process as well as to the data communication between the units. The processing unit 9 is connected via a data link 15 to a plant-side data collector unit 10 . The data link 15 is preferably realized via the Internet as either a cabled connection or wirelessly. The data collector unit 10 receives from the automation and processing units 2 , 5 , 6 , 7 via the data links 23 all local data that is necessary in the processing unit 9 for the aforesaid process control algorithms for control, regulation and analytics of the process 1 . The data link 23 shown is to be understood in functional terms, physically this can be a separate network, or the data collector unit 10 is connected to an existing network within the system 100 , for example 20 , 21 . The remote processing unit 9 executes process control algorithms 13 on the basis of input process variables 12 that are provided and prioritized by the data collector unit 10 and that are essentially based on the data generated via the effective connection 3 and outputs results 14 of these computations. The input process variables 12 can likewise be based on the historical data that is present in the automation unit 2 . As an alternative or in addition the input process variables 12 can be based on historical data that is present in the processing unit 9 itself. For example FIG. 1 presents an MPC closed-loop control structure as a process control algorithm 13 . More comprehensive data analytics can also be the subject matter of the aforesaid algorithm however. The results 14 of the process control algorithm 13 are transmitted to the automation and processing units 2 , 5 , 6 , 7 . The communication path via the data collector unit 10 can be used for this purpose or a separate communication path not shown here is used as an alternative. Within the automation unit 2 the checking module 16 can decide whether the results 14 have an impact on the process via the output element 18 .
[0039] FIG. 2 shows schematically the structure of the data collector unit 10 . The data collector unit 10 involves separate computer hardware that is equipped with one or more processors not shown here and that, in collaboration with the necessary buffers, processes the instructions held in software code. As an alternative, the data collector unit 10 can also run as a software module on one of the plant-side processing units 5 , 6 , 7 , preferably within the SCADA processing unit 5 . Via the data link 23 the data collector unit 10 receives the local data, which is needed for the further analytics or process management tasks in the processing unit external to the plant 9 . This data is stored within the data buffer (local data buffer) 24 . The data buffer collects the data from different sources. In such cases it can follow static, i.e. previously defined rules, in asking which data is to be collected from which source. Here it uses standardized interfaces (e.g. RPC, OLEDB, OPC, SQL). By default all local data is stored there. A pre-processing module pre-processes the data if necessary. Such pre-processing could include the selection of data and thus a compression of data.
[0040] The priority dispatcher 25 reads the data from the data buffer 24 and transfers said data into one of the different priority memories 26 (P1-Px). The priority dispatcher 25 has knowledge about which data item is of greater significance relative to another data item for processing within the remote processing unit 9 . More important data is given a higher priority and is thus transferred into a priority memory of a higher order of priority (e.g. P1). The priority dispatcher 25 can be configured as to whether the determination of the importance of an item of data and thus of its priority is to be done statically or dynamically. For example the priority can be determined in accordance with the actual case of process control, where e.g. data in conjunction with MCP closed-loop control structures is to be handled with higher priority. Or the priority is determined in accordance with the analytics case. Thus the priority dispatcher can be configured for example to evaluate current data of an electrical machine as higher-priority data and transfer it into the priority memory P1, while vibration data of the same electrical machine is transferred into the priority memory P2. However it can also be configured to transfer data with lower resolution (small data volume) into the memory P1, while data with high resolution (large data volume) is to be transferred into a memory of a lower order of priority.
[0041] The priority memories P1 to Px are implemented for example in the form of a FIFO (first in first out) buffer or in the form of a cyclic buffer.
[0042] As a result the priority memories P1 to Px contain the local data that is necessary for the processing unit 9 , arranged in order of priority. The cloud communication module 27 sends the data to the remote processing unit 9 , taking into consideration the assigned priority. The priority memory P1 is transferred first, then followed in sequence by the priority memories of the following orders. If for example the priority dispatcher 25 assigns an item of data to the memory P1, wherein the cloud communication module 27 is still transferring data out of the memory P3, this transmission is suspended in order to transfer the item of data out of P1. Once the transmission of this item of data is completed, the transmission of the data from the memory P3 is continued. The communication bandwidth analyzer 28 monitors the available bandwidth (data throughput) during the transmission to the processing unit external to the plant and makes this information available via the connection 30 to the priority dispatcher 25 , which on the basis of this information for example adapts the prioritization and thus the assignment to the memories P1-Px, or which on the basis of this information dynamically creates or deletes priority memories. In addition the priority dispatcher can also notify the module 24 via the effective connection 31 and instruct it not to store selected data and sort said data out using its pre-processing.
[0043] The scheme described above will now be described in more concrete terms on the basis of the example given below. If a closed-loop control deviation from a target value over time for an industrial process is considered, then this target value deviation is the key parameter for the closed-loop control algorithm. The deviation is a function of the time and is read in from the process periodically via the effective connection 3 and thus with a certain resolution. The higher the resolution, the better the process variable computations can be done. For short response times however it is important for the process variable computations to take place within a defined short time (real time). The analytics modules that run in the remote processing unit external to the plant cannot therefore wait for the entire data record in full resolution in order to compute the process variables. In this case the priority dispatcher 25 will thus receive the local data from the data buffer 24 within a specific time in full resolution. The priority dispatcher 25 samples the serial data and for example assigns every 5 data item (data item N % 5) to priority memory 1, while each third intermediate data item (data item N % 5+3) is placed in priority memory 2. All further intermediate data (data items N % 5+1, N % 5+2, N % 5+4) are buffered in priority memory 3. Priority memory 1 is then transmitted to the remote processing unit 9 . In this way the analytics module 13 , for process variable computation 14 in the remote processing unit 9 initially receives the lowest-resolution data 12 , but starts the computation 13 immediately. Provided the data can subsequently be transferred from the memories 2 and 3 without any great delay, this is taken into account in the computation 13 . In the event of inability to transfer data within the required latency time, the computation 13 of the process variables is based exclusively on the lower-resolution data. In any event however it is insured that analytics results 14 are available for the process 1 .
[0044] While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit and scope of the present invention. The embodiments were chosen and described in order to explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
[0045] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and includes equivalents of the elements recited therein: | In a system and a method for control and/or analytics of an industrial process and especially a system and a method for the prioritization of the data transmission of process data from plant-side automation and processing units to remote processing units external to the plant, the system has an the plant side at least one automation or processing unit, which carries out first process variable computations and acts on the process. On the side external to the plant, the system has a remote processing unit that carries out a number of second process variable computations and that receives local data from the at least one automation or processor unit via a data connection and at least one data collector unit. The data collector unit prioritizes the data transfer via the data connection between the at least one automation or processor unit and the processing unit external to the plant. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electromagnetic interference reducing apparatus and, more particularly, to an assembly for reducing the amount of electromagnetic interference escaping from an equipment enclosure out of which pass a plurality of electrical conductors.
2. Background Art
Many electronic systems are known which emit electromagnetic radiation in their operation. Such radiation is also known, depending on its nature, to affect other electronic systems. In order to control electromagnetic interference between electronic systems, the various government agencies have specified maximum levels of electromagnetic radiation emissions which may be allowed. These levels must be met for the equipment to be sold. An optimum method for restricting electromagnetic emissions is to totally enclose the electronic system in a shielded housing thereby restricting all emissions there from.
In the area of certain types of systems with widely separated elements such as telephone switching system, total sytem enclosure is not possible because subscriber related wiring must leave the system enclosure. In such conditions, allowable levels of emissions have been found obtainable by treating the individual wiring conductors to remove electromagnetic interference traveling on them before the conductors leave the enclosure. A common way to treat such conductors is to capacitively couple the individual conductors to the enclosure at the point they pass through a wall of the enclosure. In this regard, it is known to provide capacitive bypassing in the form of an array of feed through capacitors mounted in a conductive plane and having a first feed through terminal on a inner surface, a second feed through terminal on the outer surface and having a ground sleeve connected to the enclosure wall. A plurality of conductors passing out of the enclosure are first terminated to the inner feed through terminals. A corresponding plurality of second conductors are then connected to the outer feed through terminals and routed to the subscribers' telephone equipment. Such an arrangement, while operating generally satisfactorily, requires the individual manual connection of conductors on the feed through assembly mounted to the enclosure.
Another known method of treating conductors passing out of an enclosure to subscribers' telephone equipment is to mount a plurality of capacitors on a printed wiring board which is then mounted to an inner surface of a wall of the enclosure by means of screw fasteners. A first printed conductor on the board provides a circuit path to connect a first terminal of each of the capacitors to the enclosure wall and a plurality of second circuit conductors connect a second terminal of each of the capacitors to a corresponding first and second plated-through hole. The free ends of the conductors passing out of the enclosure and then soldered to a corresponding first plated-through hole. A second cable is provided and connected between the second plated-through hole and the equipment within the enclosure. Such an arrangement while operating generally satisfactorily requires the separate assembly of capacitors and printed wiring card to the enclosure and the assembly of the cables to the printed wiring card mounted within the enclosure.
The above arrangements have generally been found to be bulky, expensive and costly to install, and in the case of the printed wiring card of reduced effectiveness due the placement of treating capacitors at a less than ideal position for effective electromagnetic interference reduction.
SUMMARY OF THE INVENTION
The present invention provides an improved method of connecting electromagnetic interference reducing capacitors to conductors passing out of an equipment enclosure utilizing a non-conductive support plate on the opposite sides of which are formed a pair of conductive layers. The conductive layers are connected to a wall of the enclosure and each includes a plurality of apertures spaced about its surface. Within each of the apertures is formed a second conductive pad which is insulated from the associated conductive layer. A plurality of electromagnetic interference reducing capacitors are attached to the conductive layer via a first terminal and to a respective one of the pads via a second terminal, connection to the surfaces and the pads being provided for electrical reasons and for structural support. A respective one of each of the conductors passing out of the enclosure is connected to each of the capacitors second terminals to provide treatment of the conductors to reduce electromagnetic interference carried on the conductors thereby preventing the interference from escaping from the enclosure on the conductors.
Connection of the conductive layers to the enclosure wall is achieved by an electrically conductive housing connected to the enclosure wall. A wire is provided and connected between each of the conductive layers and the housing to complete the electrical connection between the conductive layer and the enclosure.
Alternately, the conductive layers may each be formed on a flexible support layer, which layers are then rolled up toward each other to form a resilient coil urging the conductive layer into direct electrical contact with the housing. The housing may be positioned on an inner side of the enclosure wall to prevent damage to the enclosure and to improve electromagnetic interference reduction. The housing may be adapted to removably receive and support the support plate, the conductive layers and the electromagnetic interference reducing capacitors.
An insulating alignment guide for the conductors is provided to position the conductors in contact with the capacitor second ends to thereby facilitate connection of the conductors with the capacitors.
In an alternate embodiment, insulation displacing terminals are each connected to an associated capacitor second end via a corresponding conductor pad attached to the support plate and are used to establish electrical connection between the conductors and the capacitor second ends. In this regard, the conductor alignment guide is used to position conductors for assembly in the terminals. The alignment guide is then pressed towards the support plate to engage the conductors with the terminals displacing the conductor insulation thereby establishing electrical connection therebetween.
The insulation terminals may be alternately arranged to accept a pair of conductors, the first inserted conductor connected to equipment within the enclosure and the second conductor connected to equipment external to the enclosure.
Finally, the assembly of the present invention may include an enclosure of non-conductive material, rectangular in shape, of split identical construction and sized to fit within the housing. The enclosure is adapted at opposite ends to accept and clamp the cable passing out of the enclosure. Formed inwardly of each of the cable clamps there is provided a wire distribution channel wherein individual cable conductors may be distributed to the alignment guide conductor slots. Laterally formed in an inner surface of each enclosure half is a receiving channel adapted to accept the alignment guides.
BRIEF DESCRIPTION OF THE DRAWING
A better understanding of the present invention maybe had by consideration of the following description taken in conjunction with the accompanying drawing in which;
FIG. 1 is a perspective view of the present invention;
FIG. 2 is a perspective view of a first embodiment showing capacitor connection and wire guide details;
FIG. 3 is a perspective view of a second embodiment showing an insulation displacing terminal arrangement for connecting the conductors to the capacitors;
FIG. 4 is a cross sectional view taken along the line 4--4 in FIG. 1 showing an alternate arrangement for connecting the conductive layer to the housing sleeve; and
FIG. 5 is a cross sectional view taken along the line 5--5 in FIG. 3 showing the use of insulation displacing terminals to provide connection to the interference reducing capacitors and simultaneously to splice two separate conductors together.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 there is shown an electromagnetic interference reducing assembly in accordance with the present invention attached to a wall 1 of an enclosure containing electromagnetic interference generating equipment (not shown). An opening 2 is provided in the wall 1 to permit a cable 3 including conductors 4 to pass there through to external equipment (also not shown). A housing 5 including a sleeve 6 of rectangular construction attached to a flange 7 is provided. The flange 7 includes an opening 8 in the flange 7 just large enough to permit passage of the cable 3 there through. The flange 7 is attached to the wall 1 by means of removable fasteners 9 such as screw fasteners.
An enclosure 12 is provided including an upper half 13 and an identical lower half 14. Each of the halves 13 and 14 including an inner surface 16 and 17, respectively. The enclosure halves are fastened together by a plurality of removable fasteners 19 such as screws. The upper half 13 and the lower half 14 of the enclosure 12 are each of rectangular construction including an inner wall 20, an outer wall 21, a left side wall 22 and a right side wall 23. Within each of the halves 13 and 14 of the enclosure 12 there is formed, adjacent to the inner wall 20 and outer wall 21, a cable clamping area 27. Inward of the cable clamping area 27 within each enclosure half is formed a wire distribution channel 29.
A wire alignment guide channel 32 is formed in each of the halves 13 and 14 of the enclosure 12 extending laterally between the left side surfaces 22 and right side surfaces 23. The channels 32 open laterally into each of the wire distribution channels 29.
An upper wire alignment guide 36 and a lower wire alignment guide 37 are provided within the channels 32, each of the guides 36 and 37 including a plurality of conductor guide slots 39 extending in a longitudinal direction from an inner edge 41 to an outer edge 42 of the alignment guides 36 and 37, the conductor guide slots 39 opened toward an inner surface 43 of guides 36 and 37. A plurality of apertures 45 are provided, each extending from the inner surface 43 of the alignment guides 36 and 37 to an outer surface 46, each intersecting a corresponding one of the conductor guide slots 39.
A support plate 50 of electrically insulating material is provided including an upper conductive layer 51 formed on an upper surface 52 thereof (see FIG. 2). Similarly a lower conductive layer 53 is formed on a lower 54 surface thereof (not shown). The conductive layers 51 and 53 are each connected to the housing sleeve 6 by corresponding ground wires 55 and 56. The ground wires 55 and 56 may be connected to the conductive layers 51 and 53 and to the sleeve 6 of the housing 5 by means of soldered connections. Each of the conductive layers 51 and 53 includes a plurality of apertures 57 formed therein. The apertures 57 are spaced about the conductive layers 51 and 53. A pad 58 is formed within each of the apertures 57 on the upper surface 51 and lower surface 54 of the support plate 50. The pads 58 are not electrically connected with the conductive layers 51 and 53.
Referring now to FIGS. 1 and 2, a plurality of capacitors 60 are included, each capacitor including a first terminal 61 connected to a corresponding one of the conductive layers 51 or 53 and a second terminal 62 connected to a respective one of the pads 58. The cable conductors 4 may have their insulation 65 selectively stripped off in the vicinity of the second contact 62 of the capacitors 60 exposing the metallic conductors 66 located therein.
Referring now to FIG. 2, the metallic conductor 66 is connected to the second terminal 62 of the capacitor 60 by any means known to the those skilled of the art. In this regard, the metallic conductor 66 may be connected to the second terminal 62 of the capacitor 60 by means of a soldered connection 68. The second terminal 62 and the first terminal 61 may be additionally connected to the pad 58 and the conductive layer 51 also by means of soldered connections 69 and 70, respectively.
Continuing to refer to FIGS. 1 and 2, the present invention may be operated by passing the cable 3 through the opening 2 in the equipment enclosure wall 1. The cable 3 is then threaded through the opening 8 in the flange 7 and the sleeve 6 of the housing 5, and the conductors 4 terminated to the electromagnetic interference generating equipment (not shown) within the enclosure. The housing 5 is then fastened to the inner surface of the enclosure wall 1.
The conductors 4 of the cable 3 are then exposed at the point the cable passes out of the equipment enclosure through the wall 1 by removing the cable outer jacket insulation. The individual conductors are separated, selectively stripped of the insulation 65 to expose the metallic conductors 66 and each is placed within a different one of the conductor guide slots 39 of the wire alignment guides 36 and 37 with the exposed conductor 66 positioned within the respective aperture 45. An assembly is prepared consisting of the support plate 50, the conductive layers 51 and 53 to which have been attached a plurality of the capacitors 60 with the first terminal 61 of each capacitors connected to a corresponding one of the conductive layers 51 and 53 and the second terminal 62 of each of the capacitors 60 connected to a corresponding one of the pads 58. The prepared assembly is inserted between the guides 36 and 37 and guides closed about the assembly to thus position each of the metallic conductors 66 in contact with a respective one of the second terminals 62. The conductors 66 are then electrically connected to the second terminal 62 by means generally known in the art. In this regard, the conductors 66 may be joined to the second terminal 62 by means of soldering. The ground wires 55 and 56 may then be electrically connected to the conductive layers 51 and 53 also by known means such as soldering.
Next, the subassembly thus assembled may be enclosed within the upper half 13 and the lower half 14 of the enclosure 12 and the enclosure halves secured to each other with the fasteners 19. As the enclosure halves are assembled, care is necessary to insure that the cable 3 is properly positioned to engage the cable clamps 27 and also to insure that the conductors 4 are properly positioned within the wire distribution channels 29.
Finally, following fastening of the enclosure halves 13 and 14 together as described above, the assembly just built is slid into the sleeve 6 of the housing 5 and the ground wires connected to the housing 5 by known means such as soldering to complete assembly and insulation of the electromagnetic interference reducing means of the present invention.
Referring now to FIG. 3, there as shown an alternate embodiment connecting the metallic conductor 66 of the conductor 4 to the second terminal 62 of the capacitor 60 without the necessity of stripping away the insulation 65. In this embodiment, an insulation displacing terminal 75 is included attached to the pad 58 by known means such as a solder connection 76. The terminal 75 is adapted to receive in a slot 77 formed therein the metallic conductor 66 of the cable conductor 4. The aperture 45 formed in the alignment guide 13 is repositioned to surround the insulation displacing terminal 75 and provide clearance for the terminal. A capacitor receiving cavity 78 is formed in the inner surface 43 of the wire alignment guide 36 to provide clearance for capacitor 60 when the guide is assembled to the support plate 50.
The present invention may be operated to utilize the insulation displacing terminals 75 of the present embodiment by passing the cable 3 through the enclosure wall 1, the housing 5 and terminating it as described above. The cable conductors 4 are then exposed and separated also as described above. The conductors 4 are then positioned, without being stripped of their insulation 65, directly into the conductor guide slots 39 of the wire alignment guides 36 and 37 and the guides assembled about a subassembly consisting of the support plane 50, the conductive layers 51 and 53, the capacitors 60, the pads 58 and the insulation displacing terminals 75. As the guides are pressed together about the subassembly, the slots 39 will force the wires into the slots 77 in the insulation displacing terminal 75 thereby displacing the insulation 65 and establishing electrical connection between the metallic conductor 66 of the cable conductors 4 and the capacitors second end 62.
Referring now to FIG. 4 there is shown the present invention including an alternate-embodiment connecting the conductive layers 51 and 53 to the housing sleeve 6. In this embodiment, a pair of flexible sheets 80 and 81 are utilized in place of the rigid supporting plane 50 of FIG. 1. In this regard, the conductive layer 51 is formed on the flexible sheet 80 and the conductive layer 53 is formed on the flexible layer 81. The flexible sheets 80 and 81 and conductive layers 51 and 53 extend laterally beyond the edges of the alignment guides 36 and 37 which are provided with curvedly diverging surfaces 82 and 83, respectively. The sheets 80 and 81 are formed in rolls 84 and 85, each formed in a curvedly diverging manner following the surface 82 or 83 as may be appropriate and then formed in a circular roll (84 and 85) in a direction toward the other sheet to bring the conductive layers 51 and 53 into contact with each other and with an inner surface 86 of the sleeve 6. To retain the conductive layers 51 and 53 in contact with each other and with the inner surface 86 of the sleeve 6 there is provided within each roll a resilient rod 88. The rod 88 may be constructed any resilient electrically insulating material such as foamed rubber or plastic and may be of circular cross section as shown or of other cross section such as oval, square, rectangular, or triangular cross section. The rod 88 serves to resiliently increase the diameter of the rolls 84 and 85 causing the rolls to expand between the inner surface 86 of the sleeve 6 and the side surface 22 of the enclosure upper half 13 and enclosure lower half 14, and also adjacent the curved diverging surfaces 82 and 83 of the alignment guides 36 and 37, respectively.
Referring to FIG. 5, there as shown an alternate embodiment of the present invention wherein the splicing of two cables and the establishing connection to the electromagnetic interference reducing capacitors is provided. In this regard, there is shown a conductor 90 of a first cable and a second conductor 91 of a second cable, which conductors are to be joined electrically and connected electrically to an electromagnetic interference reducing capacitor second terminal 62 using an insulation displacing terminal 75 connected to the capacitor terminal 62 by means of a conductive pad 86. The cables may be connected to equipment either within or outside of the equipment enclosure as desired.
The present embodiment is operated by placing the first conductor 90 in the conductor receiving slot 39 of the alignment guide 36 and assembling the guide to the support plate 50 in such a manner that the insulation displacing terminal 75 engages the aperture 45 in the guide. Pressure on the alignment guide 36 in a direction towards the support plate 50 will force the conductor 90 into the slot 77 of the insulation displacing terminal 75 thereby displacing the insulation 92 of the first conductor 90 and exposing the metallic core 93 to form a pair of contact points 94 on opposite sides of the conductor 90. The alignment guide 13 is then removed and the second conductor 91 placed in the conductor guide slot 39 after which the alignment guide is again assembled to the support plate 50 as described above thereby forcing second conductor 91 into the insulation displacing terminal slot 77 thereby displacing the insulation 96 of the second conductor 91 and exposing the metallic core 97 to form a second pair of contact points 98 on opposite sides of the conductor 91.
Alternately, the conductors 91 and 90 may both be placed in the slot 39 and the alignment guide 36 assembled to the support plate 50 to sequentially connect the conductors 90 and 91 to the insulation displacing terminal 75 in one assembly operation.
Although the preferred embodiments of the preferred invention have been illustrated in their forms described in detail, it will be readily apparent to those skilled in the art and various modification may be made therein without departing from the spirit of the invention or from the scope of the appended claims. | An assembly to reduce propagation of electromagnetic interference from an equipment enclosure via cable conductors passing out of the enclosure including a capacitor connected to each corresponding conductor and to the enclosure. The capacitors are mounted on an insulating substrate to which is fixed a conductive layer. The capacitors, the support plate, and the conductive layer are contained in a housing attached to the equipment enclosure. A second enclosure is provided, received within the housing and is equipped with a pair of clamps to retain the cables connected to the capacitors from both outside of and within the equipment enclosure. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a speed controller for motor, and more particularly, to a speed controller for motor preventing interference from reverse input, which is configured to rotate only in one direction when being driven in normal and reverse directions and has a function of preventing interference caused by a reverse input to prevent a shut-down of the operation of the speed controller by dispersing the reverse input and receiving only one direction input when rotating force is reversely input from an output side.
2. Description of the Related Art
Generally, a rotation device, such as a carrier or industrial machine, obtains driving force from a motor. In this case, the rotating force output from the motor may be transferred through an additional transmission. In other cases, a transmission may be provided in the motor itself so that the rotating force may be output directly or through an additional transmission.
In a case where a transmission is provided in a motor itself, two pawls 11 and 12 are generally mounted to a driving shaft 10 as shown in FIG. 1 so that any one pawl (constant speed pawl) 11 is directly restricted to an output unit 20 and the other pawl (speed changing pawl) 12 is restricted to the output unit 20 via a speed changing means.
More specifically, the constant speed pawl 11 bent clockwise is mounted to one side of the outer circumference of the driving shaft 10 , and the constant speed pawl 11 is directly restricted at a portion 20 a to the output unit 20 . Also, the speed changing pawl 12 bent counterclockwise is mounted to the other side of the outer circumference of the driving shaft 10 , and the speed changing pawl 12 is restricted at a portion 30 a to a sun gear 30 . Then, the sun gear 30 is engaged with a planetary gear 40 , and the planetary gear 40 is engaged with the output unit 20 .
Thus, if the driving shaft 10 of the motor (not shown) rotates in a normal direction, the constant speed pawl 11 is restricted to the output unit 20 to give a normal direction output, while if the driving shaft 10 rotates in a reverse direction, the speed changing pawl 12 is restricted to a speed changing means to give a speed-changed normal direction output to the output unit 20 .
However, if the driving shaft 10 does not rotate in the transmission for a motor and rotation is reversely input from the output unit 20 by external force, the output unit 20 is rotated counterclockwise, so that the output unit 20 and the constant speed pawl 11 are restricted to each other first. Also, the output unit 20 rotating counterclockwise makes the planetary gear 40 rotate clockwise, the planetary gear 40 rotates the sun gear 30 counterclockwise, and then, the sun gear 30 is restricted to the speed changing pawl 12 .
Thus, when the output unit 20 rotates counterclockwise, the constant speed pawl 11 and the speed changing pawl 12 are all restricted, so that the transmission does not work.
SUMMARY OF THE INVENTION
The present invention is conceived to solve the aforementioned problems. An object of the present invention is to provide a speed controller for motor preventing interference from reverse input, wherein when pawls are coupled to a driving shaft, any one of the two pawls is not restricted even in any position so that the two pawls do not interfere with each other although a reverse input is made.
The present invention for achieving the objects provides a speed controller for motor preventing interference from reverse input, which gives a normal rotation and constant speed output to an output cover when a driving shaft of the motor rotates in a normal direction and a normal rotation and speed-changed output to the output cover when the driving shaft of the motor rotates in a reverse direction, wherein a key is formed to protrude on an outer circumference of the driving shaft; a pawl-mounting ring having a key groove with a greater width than the key is coupled to the key; a constant speed pawl and a speed changing pawl having opposite directions are mounted to the pawl-mounting ring so that lower portions of them extend to the key groove; and the pawl-mounting ring is frictionally fixed by an additionally fixed friction pin, whereby at least one of the constant speed pawl and the speed changing pawl is made lie down by the key according to a rotation direction of the driving shaft.
Also, the present invention provides a speed controller for motor preventing interference from reverse input, which gives a normal rotation and constant speed output to an output cover when a driving shaft of the motor rotates in a normal direction and a normal rotation and speed-changed output to the output cover when the driving shaft of the motor rotates in a reverse direction, wherein the driving shaft has a polygonal outer circumference; a ball-mounting ring is coupled to the outer circumference, the ball-mounting ring including therein a constant speed ball and a speed changing ball spaced apart from each other by a predetermined distance so that upper and lower sides of them protrude; and the ball-mounting ring is frictionally fixed by an additionally fixed friction pin, whereby at least one of the constant speed ball and the speed changing ball escapes from the outer circumference according to a rotation direction of the driving shaft.
Here, the outer circumference may have a side with a concavely curved shape.
Further, the outer circumference may have a side with a concavely angled shape.
Furthermore, the outer circumference may have a side with a wave shape.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a transmission for a motor which gives a constant speed output and a speed-changed output in one direction;
FIG. 2 is a sectional view showing a speed controller for motor preventing interference from reverse input according to a first embodiment of the present invention;
FIG. 3 is a side view showing a pawl-mounting ring of FIG. 2 ;
FIG. 4 is a sectional view showing another example wherein a friction pin shown in FIG. 2 is mounted;
FIGS. 5 and 6 are side views illustrating the operation of the pawl-mounting ring of FIG. 2 ;
FIG. 7 is a sectional view showing a speed controller for motor preventing interference from reverse input according to a second embodiment of the present invention;
FIG. 8 is a side view showing a ball-mounting ring of FIG. 7 ;
FIG. 9 is a sectional view showing another example wherein a friction pin shown in FIG. 7 is mounted;
FIGS. 10 and 11 are side views illustrating the operation of the ball-mounting ring of FIG. 7 ; and
FIGS. 12 , 13 and 14 are views of modifications of the polygonal outer circumference of a driving shaft shown in FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter, preferred embodiments of a speed controller for motor preventing interference from reverse input according to the present invention will be described in detail with reference to the accompanying drawings.
FIG. 2 is a sectional view showing a speed controller for motor preventing interference from reverse input according to a first embodiment of the present invention, FIG. 3 is a side view showing a major portion of a pawl-mounting ring of FIG. 2 , and FIG. 4 is a sectional view showing another example wherein a friction pin shown in FIG. 2 is mounted.
Referring to FIGS. 2 and 3 , a speed controller 100 for motor preventing interference from reverse input according to the first embodiment of the present invention includes a driving shaft 10 rotating in normal and reverse directions, a pawl-mounting ring 15 surrounding an outer circumference of the driving shaft 10 , a constant speed pawl 11 and a speed changing pawl 12 coupled to the pawl-mounting ring 15 , an output cover 20 restricted at a portion 20 a to the constant speed pawl 11 , a sun gear 30 restricted at a portion 30 a to the speed changing pawl 12 , a planetary gear 40 engaged with the sun gear 30 at its inner side and the output cover 20 at its outer side, and a friction pin 60 for giving frictional force to the pawl-mounting ring 15 .
First, the driving shaft 10 and the pawl-mounting ring 15 transmit rotation through a key 10 a formed on the outer circumference of the driving shaft 10 and a key groove 15 a formed on an inner side of the pawl-mounting ring 15 . The key groove 15 a is designed to have a greater width than the key 10 a.
Also, the constant speed pawl 11 and the speed changing pawl 12 mounted to the pawl-mounting ring 15 and having opposite directions are elastically supported by a spring (not shown) to always erect. In addition, lower portions of the constant speed pawl 11 and the speed changing pawl 12 extend to protrude toward the key groove 15 a . An end of the key 10 a is positioned between the constant speed pawl 11 and the speed changing pawl 12 , which are mounted to cross each other, as shown in FIG. 3 , so that the key 10 a serves to make the constant speed pawl 11 and the speed changing pawl 12 erect or lie down.
The pawl-mounting ring 15 formed as described above is rotated just by means of the key 10 a and the key groove 15 a and is frictionally fixed by means of a friction pin 60 in order not to return or run idle.
That is, the friction pin 60 is mounted to the rotating sun gear 30 or the output cover 20 as shown in FIG. 2 to press the outer circumference of the pawl-mounting ring 15 . Alternatively, the friction pin 60 may be configured such that it is mounted to a fixed frame 50 of the speed controller 100 for a motor as shown in FIG. 4 to press the outer circumference of the pawl-mounting ring 15 .
FIGS. 5 and 6 are side views illustrating the operation of the speed controller for motor preventing interference from reverse input according to the first embodiment of the present invention.
When the driving shaft 10 stops while rotating in the normal direction, the speed controller 100 preventing interference from reverse input according to the first embodiment of the present invention erects only the constant speed pawl 11 and makes the speed changing pawl 12 lie down as shown in FIG. 3 . Thus, in such a state, if rotation is reversely transferred from the output cover 20 counterclockwise, the output cover 20 transmits the reverse rotation toward both of the constant speed pawl 11 and the planetary gear 40 .
First, the rotation reversely input from the output cover 20 toward the constant speed pawl 11 is restricted at the portion 20 a to the constant speed pawl 11 while rotating counterclockwise, and the pawl-mounting ring 15 rotates counterclockwise by the rotation of the constant speed pawl 11 . Also, the pawl-mounting ring 15 rotates the driving shaft 10 in the reverse direction by means of the key groove 15 a and the key 10 a.
Then, the rotation reversely input from the output cover 20 toward the planetary gear 40 rotates counterclockwise and makes the planetary gear 40 rotate clockwise, and the planetary gear 40 rotates the sun gear 30 counterclockwise. Also, the sun gear 30 rotating counterclockwise is not restricted at the portion 30 a to the speed changing pawl 12 but runs idle, thereby not transmitting the reversely input rotation toward the driving shaft 10 .
Meanwhile, when the driving shaft 10 stops while rotating in the reverse direction, the speed controller 100 for a motor makes the constant speed pawl 11 lie down and erects the speed changing pawl 12 as shown in FIG. 5 . Also, if the driving shaft 10 stops intermediately while rotating in either the normal direction or the reverse direction, both of the constant speed pawl 11 and the speed changing pawl 12 are made lie down.
Thus, in the speed controller 100 for a motor according to the first embodiment of the present invention, one or both of the constant speed pawl and the speed changing pawl are made lie down in any state, even when rotation is reversely input from the outside.
Hereinafter, a speed controller for motor preventing interference from reverse input according to a second embodiment of the present invention will be described.
FIG. 7 is a sectional view showing a speed controller for motor preventing interference from reverse input according to the second embodiment of the present invention, FIG. 8 is a side view showing a major portion of a ball-mounting ring of FIG. 7 , and FIG. 9 is a sectional view showing another example wherein a friction pin shown in FIG. 7 is mounted.
Referring to FIGS. 7 and 8 , the speed controller 200 for motor preventing interference from reverse input according to the second embodiment of the present invention includes a driving shaft 10 rotating in normal and reverse directions, a ball-mounting ring 16 surrounding an outer circumference of the driving shaft 10 , constant speed balls 13 and speed changing balls 14 coupled to the ball-mounting ring 16 , an output cover 20 restricted at a portion 20 a to the constant speed balls 13 , a sun gear 30 restricted at a portion 30 a to the speed changing balls 14 , a planetary gear 40 engaged with the sun gear 30 at its inner side and the output cover 20 at its outer side, and a friction pin 60 for giving a frictional force to the ball-mounting ring 16 .
First, the rotation is transmitted from the driving shaft 10 to the output cover 20 and the sun gear 30 by means of the ball-mounting ring 16 surrounding the driving shaft 10 and the constant speed balls 13 and the speed changing balls 14 mounted to the ball-mounting ring 16 .
The speed controller 200 for motor preventing interference from reverse input according to the second embodiment of the present invention transmits rotation in such a manner that the driving shaft 10 surrounded by the ball-mounting ring 16 is formed to have a polygonal outer circumference 10 b and the constant speed balls 13 and the speed changing balls 14 are caught between the upper restriction portions 20 a and 30 a and the polygonal outer circumference 10 b.
Thus, the constant speed balls 13 and speed changing balls 14 of the same in number as sides of the polygonal outer circumference 10 b are mounted to the ball-mounting ring 16 such that their upper and lower sides partially protrude to the outside. The constant speed ball 13 and the speed changing ball 14 are mounted not coaxially but adjacently. Preferably, a distance between the constant speed ball 13 and the speed changing ball 14 adjacent to each other is smaller than a length of one side of the polygonal outer circumference 10 b , and the constant speed ball 13 and the speed changing ball 14 are designed to be spaced apart from the restriction portions 20 a and 30 a when being located at the center of the side of the outer circumference 10 b.
Also, a friction pin 60 is mounted to the ball-mounting ring 16 to give friction force thereto such that it does not run idle, as in the first embodiment. The friction pin 60 may be fixed to the rotating sun gear 30 and the output cover 20 or may be fixed to the fixed frame 50 .
FIGS. 10 and 11 are side views illustrating the operation of the speed controller for motor preventing interference from reverse input according to the second embodiment of the present invention.
In the speed controller 200 for motor preventing interference from reverse input according to the second embodiment of the present invention, when the driving shaft 10 stops while rotating in the normal direction, the constant speed ball 13 adjacent to a vertex of the outer circumference 10 b of the driving shaft 10 is caught to be restricted at the portion 20 a to the output cover 20 as shown in FIG. 8 . Also, the speed changing ball 14 is located at the center of the side of the outer circumference 10 b of the driving shaft 10 to become free.
In such a state, if rotation is reversely transferred from the outer cover 20 counterclockwise, the output cover 20 reversely transmits rotation toward the constant speed ball 11 and the planetary gear 40 .
First, the rotation reversely input from the output cover 20 to the constant speed ball 13 is restricted at the portion 20 a to the constant speed ball 13 while rotating counterclockwise, and the restricted constant speed ball 13 is rotated counterclockwise together with the ball-mounting ring 16 and the driving shaft 10 .
Then, the rotation reversely input from the output cover 20 toward the planetary gear 40 rotates counterclockwise and makes the planetary gear 40 rotate clockwise, and the planetary gear 40 rotates the sun gear 30 counterclockwise. Also, the sun gear 30 rotating counterclockwise is not restricted at the portion 30 a to the speed changing ball 14 but runs idle, thereby not transferring the reversely input rotation toward the driving shaft 10 .
Meanwhile, in the speed controller 200 for a motor, when the driving shaft 10 stops while rotating in the reverse direction, the speed changing ball 14 is caught to be restricted as shown in FIG. 10 , and the constant speed ball 13 becomes free. Also, if the driving shaft 10 stops intermediately while rotating in either the normal direction or the reverse direction, both of the constant speed ball 13 and the speed changing ball 14 become free.
Thus, in the speed controller 200 for a motor according to the second embodiment of the present invention, one or both of the constant speed ball 13 and the speed changing ball 14 become free in any state, even when rotation is reversely input from the outside.
FIGS. 12 to 14 are views showing modifications of the outer circumference of the driving shaft in the speed controller for motor preventing interference from reverse input according to the second embodiment of the present invention.
That is, in the speed controller 200 for motor preventing interference from reverse input according to the second embodiment of the present invention, the driving shaft 10 basically has a polygonal outer circumference 10 b , but the polygonal outer circumference 10 b may have concave sides as shown in FIG. 12 . Alternatively, the polygonal outer circumference 10 b may have concavely angled sides as shown in FIG. 13 . Moreover, the polygonal outer circumference 10 b may also have wave-shaped sides as shown in FIG. 14 .
As mentioned above, the speed controller for motor preventing interference from reverse input according to the present invention is configured such that at least one of two pawls is not restricted, thereby preventing a shut-down of the operation of the speed controller although rotation is reversely input from an output side.
Although the present invention has been described in connection with the preferred embodiments, it will be understood by those skilled in the art that various modifications and changes can be made thereto without departing from the spirit and scope of the invention defined by the appended claims. | A transmission for a motor, which gives a normal rotation and constant speed output to an output cover when a driving shaft of the motor rotates in a normal direction and a normal rotation and speed-changed output to the output cover when the driving shaft of the motor rotates in a reverse direction, is provided. Interference caused by a reverse input can be prevented although rotation is reversely input from the output cover. The driving shaft includes a polygonal outer circumference; a ball-mounting ring is coupled to the outer circumference, the ball-mounting ring including, therein a constant speed ball and a speed changing ball spaced apart from each other by a predetermined distance so that upper and lower sides of them protrude; and the ball-mounting ring is frictionally fixed by an additionally fixed friction pin. | 8 |
BACKGROUND
The present invention relates generally to bicycles, and more specifically to bicycle frames.
Bicycles commonly have a main frame and a front fork pivotally secured to the main frame. The main frame typically includes a top tube, a down tube, a seat tube, and a rear wheel mount for receiving a rear wheel axle. The front fork typically includes a front wheel mount for receiving a front wheel axle. Steering control of the bicycle is provided by a handlebar that is usually secured to the front fork via a handlebar stem.
In some situations, it is desirable to carry a bicycle. For example, it is often necessary to lift and carry a bicycle over an obstacle, such as a curb, fallen tree, or other obstruction. In fact, in competitive events known as cyclocross racing, obstacles are deliberately placed on the race course in order to force the rider to dismount the bicycle and carry the bicycle over the obstacle.
SUMMARY
The present invention provides a bicycle having a frame that facilitates carrying the bicycle. In one construction, the present invention provides a bicycle frame including a head tube, a bottom bracket that supports a crankset, and a tubular frame member that is coupled to the head tube and that includes a concave section disposed on an underside of the frame member and spaced from the head tube.
In another construction, the present invention provides a bicycle frame including a head tube, a bottom bracket adapted to support a crankset, and a tubular frame member that is coupled to the head tube and that defines a longitudinal axis. The frame member has a first length along the axis and includes a concave section disposed on an underside of the frame member. The concave section has a second length that is at most 40 percent of the first length.
In another construction, the present invention provides a bicycle frame including a head tube, a bottom bracket adapted to support a crankset, and a tubular frame member that is coupled to the head tube and that defines a longitudinal axis. The tubular frame member includes a concave section disposed on an underside of the tubular frame member. The concave section has a central recess and a curved ridge disposed along the central recess such that the central recess and the curved ridge cooperate to define a substantially oval-shaped depression in the tubular frame member.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a bicycle having a frame embodying the present invention.
FIG. 2 is a lower perspective view of a portion of the frame of the bicycle illustrated in FIG. 1 , including a top tube, a seat tube, and a down tube.
FIG. 3 . is an underside view of the down tube of FIG. 2 illustrating a concave section.
FIG. 4 is a cross-section of the down tube taken along line 4 - 4 in FIG. 3 .
FIG. 5 is a cross-section of the down tube taken along line 5 - 5 in FIG. 3 .
FIG. 6 is a cross-section of the down tube taken along line 6 - 6 in FIG. 3 .
FIG. 7 is a cross-section of the down tube taken along line 7 - 7 in FIG. 3 .
FIG. 8 is a cross-section of the down tube taken along line 8 - 8 in FIG. 3 .
FIG. 9 is a perspective view of a portion of the down tube taken along line 9 - 9 in FIG. 2 .
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
FIG. 1 shows a bicycle 10 (e.g., a cyclocross bicycle) that includes a front wheel 15 , a rear wheel 20 , and a frame 25 . The frame 25 has a head tube 30 and a front fork 35 rotationally supported by the head tube 30 and that secures the front wheel 15 to the frame 25 . A handlebar 40 and a stem assembly 45 secures the handlebar 40 to the front fork 35 such that movement of the handlebar 40 results in movement of the stem assembly 45 and the fork 35 .
FIGS. 1 and 2 show that the frame 25 also has a top tube 50 connected to and extending rearward from the head tube 30 , and a down tube 55 connected to the head tube 30 below the top tube 50 and extending generally downward toward a bottom bracket 60 of the frame 25 . A seat tube 65 extends upward from the bottom bracket 60 and is connected to the top tube 50 , and a seat 70 is supported by the seat tube 65 .
The illustrated down tube 55 is coupled to the head tube 30 and to the bottom bracket 60 , and extends in a generally downward and rearward direction from the head tube 30 to the bottom bracket 60 . Referring to FIGS. 1-3 , the down tube 55 defines a longitudinal axis 75 . The down tube 55 has a length L 1 that is measured along the axis 75 and a width W 1 that is measured across the axis 75 . Generally, the length L 1 is measured from the intersection of the head tube 30 and the down tube 55 to the center of the bottom bracket 60 along the axis 75 . The down tube 55 illustrated in FIGS. 1-3 has a length L 1 of approximately 650 mm, although the length L 1 can be any other suitable length.
With reference to FIGS. 2 and 3 , the down tube 55 includes a concave section 80 that is disposed on an underside (i.e., facing generally downward toward the ground) of the down tube 55 to accommodate a hand of a bicycle rider. Alternatively, or in addition, the top tube 50 can include a concave section (not shown) that is similar to the concave section 80 .
The illustrated concave section 80 is located between and spaced from the head tube 30 and the bottom bracket 60 . As shown in FIG. 2 , the concave section 80 is located closer to the head tube 30 than the bottom bracket 60 , although the concave section 80 can be located near the middle portion of the down tube 55 , or even closer to the bottom bracket 60 than the head tube 30 , if desired. With reference to FIG. 3 , the concave section 80 is substantially symmetrical about a vertical plane P 1 (as viewed in FIG. 3 ) passing through the longitudinal axis 75 , and is substantially symmetrical about a transverse plane P 2 (as viewed in FIG. 3 ) that is perpendicular to the longitudinal axis 75 .
The concave section 80 has a length L 2 (e.g., 75-110 mm) measured along the longitudinal axis 75 , and a width W 2 (e.g., 10-27 mm) measured laterally across the axis 75 . Generally, a ratio of the width W 2 relative to the length L 2 (W 2 /L 2 ) for the concave section 80 is equal to or less than 0.25 to substantially correspond or conform to the ratio of the length of a portion of a person's fingers (e.g., the approximate length of one node of the fingers) relative to the width of the person's hand as measured across the fingers when the hand is loosely clenched. As illustrated, the width W 2 of the concave section 80 is approximately 16 mm such that the ratio W 2 /L 2 is approximately 0.15. Also, the length L 2 of the concave section 80 depicted in FIG. 3 is approximately 105 mm such that the length L 2 is approximately 16 percent of the length L 1 of the down tube 55 . Preferably, the length L 2 of the concave section 80 is at most 40 percent of the length L 1 of the down tube 55 to accommodate a person's hand while maintaining stiffness of the down tube 55 . In some constructions, the length L 2 is at most 30 percent of the length L 1 . In other constructions, the length L 2 is at most 20 percent of the length L 1 .
With reference to FIGS. 2 , 3 , and 9 , the concave section 80 has a central recess 85 and a curved ridge 90 that defines a transition or boundary between the central recess 85 on the underside of the down tube 55 and the other surfaces of the down tube 55 . Stated another way, the central recess 85 is formed in the down tube 55 such that concave section 80 defines a depression in the underside of the down tube 55 . As illustrated, the curved ridge 90 extends circumferentially around the central recess 85 to define a substantially oval-shaped depression, as best shown in FIG. 3 . Generally, the oval shape of the illustrated depression encompasses any smoothly-rounded, closed, convex shape (e.g., an ellipse).
As illustrated in FIG. 4 , the illustrated down tube 55 has an oblong or rounded trapezoidal (e.g., pentagonal) cross-sectional profile in the area between the head tube 30 and the concave section 80 . In particular, the upper side of the down tube 55 at this location is rounded and is at least partially defined by a convex radius of curvature R 1 . The underside of the down tube 55 is slightly less rounded than the upper side, which is at least partially defined by a convex radius of curvature R 2 . At the location shown in FIG. 4 , the down tube 55 has a first height H 1 (e.g., 53 mm).
FIG. 5 illustrates the cross-sectional profile of the down tube 55 near a forward end of the concave section 80 (i.e., the area of the concave section 80 toward the head tube 30 ). At this location, the down tube 55 transitions from the oblong cross-sectional profile to a profile that has a rounded profile on the upper side and a substantially flat or slightly inwardly curved (i.e., concave) profile on the underside due to the central recess 85 . In FIG. 5 , the central recess 85 and the ridge 90 cooperate to define the profile of the underside of the down tube 55 . As illustrated, at least a portion of the upper side has a convex radius of curvature R 1 at this location, at least a portion of the central recess 85 has a concave radius of curvature R 2 , and at least a portion of the laterally opposed portions of the curved ridge 90 each has a convex radius of curvature R 3 .
FIG. 6 illustrates that, at a longitudinal center of the concave section 80 , at least a portion of the upper side of the down tube 55 has a convex radius of curvature R 1 , at least a portion of the central recess 85 defines a concave radius of curvature R 2 , and at least a portion of the laterally opposed portions of the curved ridge 90 define convex radii of curvature R 3 such that the down tube 55 has a substantially kidney bean profile in cross-section. Stated another way, the radius of curvature R 1 is larger than the radius of curvature R 2 , and the radii of curvature R 1 and R 2 are each larger than the radii of curvature R 3 . At the location shown in FIG. 6 , the down tube 55 has a second height H 2 (e.g., 50 mm) that is smaller than the first height H 1 .
FIG. 7 illustrates the cross-sectional profile of the down tube 55 near a rearward end of the concave section 80 (i.e., the area of the concave section 80 toward the bottom bracket 60 and farthest from the head tube 30 ). At this location, the down tube 55 transitions from the kidney bean profile defined by the concave section 80 ( FIG. 6 ) to an oblong cross-sectional profile that is very similar to the profile illustrated and described with regard to FIG. 5 . As illustrated, at least a portion of the upper side has a convex radius of curvature R 1 at this location, at least a portion of the central recess 85 has a concave radius of curvature R 2 , and at least a portion of the laterally opposed portions of the curved ridge 90 each has a convex radius of curvature R 3 .
FIG. 8 shows that the down tube 55 has a substantially outwardly rounded or convex cross-sectional profile in the area between the concave section 80 and the bottom bracket 60 . At the location illustrated in FIG. 8 , at least a portion of the upper side of the down tube 55 has a convex radius of curvature R 1 , and at least a portion of the underside has a convex radius of curvature R 2 . At the location shown in FIG. 8 , the down tube 55 has a third height H 3 (e.g., 49 mm) that is smaller than the second height.
Table 1, produced below, sets forth the approximate dimensions and the relationship between the radii of curvature R 1 , R 2 , R 3 for the cross-sectional profile of the down tube 55 as illustrated in FIGS. 4-8 , which correspond to locations 4 - 8 .
Location 4
Location 5
Location 6
Location 7
Location 8
(FIG. 4)
(FIG. 5)
(FIG. 6)
(FIG. 7)
(FIG. 8)
R1
31 mm
26 mm
23 mm
25 mm
37 mm
R2
94 mm
108 mm
56 mm
108 mm
53 mm
R3
NA
15 mm
10 mm
10 mm
NA
With reference to FIG. 6 , at the longitudinal center of the concave section 80 , the radius of curvature R 2 for the curved ridge 90 is preferably between about 5 mm and 15 mm, and the width W 1 of the down tube 55 is preferably between about 30 mm and 75 mm. Generally, the radius of curvature R 2 of the curved ridge 90 at the longitudinal center is preferably between about 8 percent and 35 percent of the width W 1 of the down tube 55 to avoid relatively sharp edges on the down tube 55 . The illustrated down tube 55 at the longitudinal center has a radius of curvature R 2 of approximately 10 mm, and a width W 1 that is approximately 59 mm. As such, the illustrated radius of curvature is approximately 17 percent of the width W 1 .
As illustrated in FIGS. 4-9 , the upper side surface profile of the down tube 55 has a substantially rounded profile that is maintained along the entire length of the down tube 55 . The underside of the down tube 55 transitions from the less-rounded profile between the head tube 30 and the concave section 80 to the inwardly curved or kidney bean profile defined by the central recess 85 , and then to the more-rounded profile between the concave section 80 and the bottom bracket 60 .
With reference to FIGS. 1-3 and 9 , the depression defined by the central recess 85 provides an area of the down tube 55 that a user, such as a cyclocross rider, can securely and comfortably grasp. Stated another way, the profile of the down tube 55 at the concave section 80 is ergonomically designed to substantially conform to the profile of the rider's hand so that the bicycle 10 can be comfortably and stably lifted (e.g., over an obstacle, or so that the top tube 50 rests on the rider's shoulder) by the rider. In particular, the upper rounded profile of the down tube 55 conforms to the area between the rider's index finger and the thumb, whereas the central recess 85 and the ridge 90 conform to the profile of the padded side of the rider's fingers. The illustrated concave section 80 is located closer to the head tube 30 than the bottom bracket 60 (i.e., substantially forward of a longitudinal center of the down tube 55 ) so that the rider does not have to reach too far to firmly grasp the down tube 55 .
Various features and advantages of the invention are set forth in the following claims. | A bicycle frame including a head tube and a bottom bracket adapted to support a crankset. The frame also includes a tubular frame member that is coupled to the head tube and that has a concave section disposed on an underside of the frame member and spaced from the head tube. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a grasping forceps for use in conjunction with endoscopic instruments, for example a ureteroscope, wherein the forceps, with an appropriate grasping distal end, extends through and is manipulated beyond the positioned instrument for capturing the target, for example, a stone, stent, clump of tissue, or the like.
Such forceps, as well as the above referred to relationship thereof to endoscopic instruments, are well known in the art and are principally intended for manual control by a single hand wherein both the thumb and fingers are used for manipulation of the functioning components.
A common form of grasping forceps utilizes three or four flexible grasping prongs or claws outwardly diverging from the end of a flexible shaft or cable and selectively retracted into grasping engagement upon telescopic retraction within a cable surrounding sleeve which inwardly biases the claws into generally coaxial alignment with the cable. However, inasmuch as the distal ends of the collapsed claws frequently remain exposed, both the claws and the interior of the scope tend to become damaged during passage of the forceps through the scope's working channel. Any such damage or disruption during a surgical procedure is clearly undesirable.
Avoidance of this problem of potential damage to both the scope and the forceps by an extension of the collapsing sleeve beyond the ends of the claws also raises significant problems. More specifically, in light of the normally sharpened and in-turned nature of the tips of the forcep claws, any complete collapsing and interengagement of these tips will result in a tendency of the tips to interlock or jam together whereby automatic opening of the claws either will not occur at all upon retraction of the collapsing sleeve, or will do so in an uneven and unpredictable manner, neither situation of which would be acceptable.
Another problem commonly encountered with known grasping forceps is the difficulty in maintaining the gripping or grasping claws, during collapsing engagement with the object, at a fixed axial location relative to the end of the scope and the target object itself. In other words, many forceps effect the closing of the claws by an axial retraction of the claws into a collapsing sleeve which results in a tendency to simultaneously retract from the target object.
SUMMARY OF THE INvENTION
The forceps of the present invention, particularly adapted for use in conjunction with ureteroscopes and the like, is constructed for introduction and manipulation through a scope in a manner which protects both the scope and the forceps against possible damage as the forceps move through the interior channel of the scope. This is achieved by a unique means of closing and enclosing the claws without affecting the complete operability thereof at the target site.
In conjunction therewith, it is a significant object of the invention to provide for the complete protective enclosure of the jaws, while moving through the scope, without locking of the jaws with the tips interengaged in a manner as might prevent a free opening of the jaws.
In achieving the above, the forceps includes a closure sleeve closely about the claw cable in conjunction with means for manipulating the closure sleeve between a retracted position rearward of the claws sufficient to allow for full resilient expansion of the claws, and a forward position telescoped over the claws a sufficient distance to effect an inward collapsing of the claws without completely enclosing the claws. Specifically, the closure sleeve terminates sufficiently rearward of the in-turned tips of the claws to bring the claws into generally coaxial alignment with the main shaft or cable body and to generally nest the tips without interlocking or jamming the tips such as might prevent free opening of the claws.
The closure sleeve is in turn surrounded by a reciprocating sheath which, in the forwardmost position thereof, encloses both the leading portion of the closure sleeve and the closed or collapsed claws, the sheath extending slightly forward of the claw tips to insure a complete protective enclosure thereof. It will be recognized that the sheath, having an internal diameter greater than the external diameter of the closure sleeve, will effectively surround and enclose the claw tips without exerting any direct closure force on the claws. Thus, the claws are completely contained and protected while the potential for disruption of the operative manipulation of the claws is avoided.
In use, the sheath is maintained fully extended for protectively enclosing the claws as the claws move through the scope, thus avoiding any potential for damage to either the scope or the claws. Once engaged through the scope, and preferably as the distal or claw end approaches the target site, the claws and the closure sleeve are allowed to advance out of the sheath, exposing the sleeve-closed claws for manipulation of the claws through an initial retraction of the closure sleeve, an engagement of the claws with the object to be grasped, and a subsequent forward extension of the closure sleeve to grasp the target object for removal with the claws.
Other objects and advantages of the invention, the specifics of which will become more apparent from the following detailed description of the invention, include the provision of forceps which allow for manipulation of the claws, during both opening and closing, in a manner whereby the axial position of the claws, that is relative to both the scope and the target object, does not change. This is significant in enabling a closing of the claws about the target object without a simultaneous retraction relative to the target object as might affect engagement therewith. Such an arrangement is basically achieved by utilizing a fixed length claw cable in conjunction with a reciprocating closure sleeve which slides thereon.
Other objects include the provision of a unique control system for single-handed manipulation of both the closure sleeve and the sheath in an ergonomically superior configuration which allows for both better control and the fabrication of very small 3 Fr. instruments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the grasping forceps of the invention with the claws extended or opened;
FIG. 2 is a top plan view of the forceps in its fully closed position and with a portion of the handle partially in section;
FIG. 3 is a similar top plan view with the sheath retracted;
FIG. 4 is a similar top plan view with the closure sleeve retracted and the claws open;
FIG. 5 is an enlarged sectional detail taken substantially on a plane passing along line 5--5 in FIG. 2;
FIG. 6 is an enlarged cross-sectional detail taken substantially on a plane passing along line 6--6 in FIG. 3;
FIG. 7 is a cross-sectional detail taken substantially on a plane passing along line 7--7 in FIG. 4;
FIG. 8 is a cross-sectional detail taken substantially on a plane passing along line 8--8 in FIG. 6;
FIG. 9 is a front elevational view of the open claws;
FIG. 10 is an enlarged cross-sectional detail taken substantially on a plane passing along 10--10 in FIG. 2;
FIG. 11 is a plan view of a portion of a modified form of a forceps handle with means for selectively fixing the position of the sheath;
FIG. 12 is a cross-sectional detail taken substantially on a plane passing along line 12--12 in FIG. 11;
FIG. 13 is a cross-sectional detail of another means for releasably fixing the position of the sheath;
FIG. 14 is an exploded perspective detail of the construction of FIG. 13; and
FIG. 15 illustrates a further exemplary means of fixing the sheath in a predetermined position.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring more specifically to the drawings the forceps 20 includes an elongate handle 22 ergonomically configured to be held and manipulated by one hand. An elongate chamber 24, defined longitudinally through the handle 22, opens through the distal end 26 of the handle. The chamber 24, at the proximal end 28 of the handle 22, is closed by a plug-type end cap 30 affixed therein and providing an end piece to the handle 22 which is peripherally coextensive therewith. Both the handle 22 and the axial chamber 24 therein are preferably of constant rectangular cross-sectional configurations to facilitate a firm non-rotational gripping of the instrument.
The handle is completed by an elongate slot 32 defined through the top wall 34 of the housing 22 along substantially the entire length thereof from the rearwardly mounted plug cap 30 to a point just rearward of the leading or distal end 26 of the handle 22 whereby an integral transverse crossbar 36 is defined. The top wall 34, longitudinally along and the opposite sides of the slot 32, extends inwardly from the respective side walls 38 of the handle 22 and defines chamber-overlying shoulders 40.
The actual gripping component of the forceps 20 comprises an elongate fixed length flexible shaft or cable 42 with a distal end comprising a gripping or grasping head 44 with triradiate claws 46. The claws 46, when unconfined, assume a forwardly diverging outwardly spread relationship with each other terminating in free gripping ends or tips 48. The claws 46, as shall be described subsequently, are capable of being resiliently laterally inwardly collapsed into general coaxial alignment with the cable. As desired, the cable can be defined by separately wound wires each terminating in one of the aforesaid claws. Alternatively, the cable can be of a single extrusion with the claws defined therefrom.
The shaft or cable 42 extends longitudinally through the hollow handle 22 and both through and for a substantial extent beyond the open forward end 26 thereof. The proximal end 50 of the cable 42 is received centrally within the end plug 30 through a vertical slot 52 and is fixed therein by appropriate set screw means 54 threaded inward through the upper end of the plug 30 immediately outward of the near or proximal end of the handle 22. The cable 42, and hence the gripping head 44 is thus longitudinally fixed relative to the handle 22, with the cable 42 extending generally axially through the handle.
The opening and closing of the claws 46 are effected utilizing a closure sleeve 56, preferably formed of stainless steel for maximum strength and flexibility, and resistance to developing kinks as might weaken or otherwise affect the operation of the sleeve. The sleeve 56 is closely received about the cable 42 for longitudinal reciprocation thereon relative to the gripping head 44.
Longitudinal reciprocation of the closure sleeve is controlled by a thumb-manipulating control knob 58 which extends through and is guided for longitudinal movement along the elongate slot 32. The control knob 58 includes an outer portion 60, configured for a non-slipping engagement by the thumb of the user, which transversely spans the slot 32 and overlies the top wall 34 of the handle 22 to the opposite sides of the slot. The knob also includes an inner or lower block-like body portion 62 received within the handle chamber 24 and defining a pair of upwardly directed opposed side ledges 64 which engage beneath the opposed shoulders 40 defined by the top wall 34 to the opposite sides of the slot 32. The knob 58 is thus confined to movement solely axially relative to the handle 22.
A mounting tube 66 of slightly greater length than the knob 58 is longitudinally received through and fixedly secured within the lower portion 62 of the knob 58. The closure sleeve 56 is in turn longitudinally received through the mounting tube 66 and fixedly secured therein, for example by swaging the leading end of the tube 66 and/or by adhesive. The use of the relatiVely rigid tube 66 assures a proper locking engagement of the highly flexible closure sleeve to the control knob 58.
The closure sleeve 56, in the forwardmost position thereof, as best noted in FIGS. 3, and 10, has the distal end 70 thereof extended sufficiently forward over the claws 46 to effect an inward collapsing of the claws into general axial alignment with the main cable or shaft 42, while at the same time terminating short or rearward of the extreme tips 48 of the claws. This is particularly significant in that in view of the close-tolerance engagement of the sleeve 56 over the cable 42 and the claws 46 as the closure sleeve 56 is forwardly moved to effect the closing of the claws 46, and in light of the in-turned, overlapping and possibly sharp nature of the claw tips 48, any extension of the closure sleeve 56 beyond a forward position sufficient so as to collapse the claws 46 into substantially alignment with the main cable 42, and, in particular movement of the closure sleeve 56 to completely enclose the tips 48, results in a tendency for the claw tips 48 to wedge or interlock and affect the operation of the grasping head 44.
More particularly, the direct engagement of the closure sleeve 56 with the claw tips 48 forces the tips 48 into a sufficiently tight engagement with each other as to prevent, or at least detrimentally affect the automatic spring-biased opening of the claws 46 as the closure sleeve 56 is retracted. This is clearly an unacceptable situation in the environment of the invention.
The desired forwardmost positioning of the distal end 70 of the closure sleeve 56 is defined by the abutment-forming cross piece or crossbar 36 of the top wall 34 against which the control knob 58 forwardly engages. The retraction of the control knob 58, and hence the closure sleeve 56, is also limited as shall be described subsequently.
While the exposure of the claw tips 48 in the closed position of the grasping head 44 is highly desirable, in assuring proper operation of the claws 46, this does give rise to a substantial problem during passage through the interior of the scope or the working channel therethrough. Basically, the exposed forward or tip portions 48 of the claws 46, even in the closed position of the grasping head 44, will tend to both damage the interior of the scope, and themselves become damaged by engagement with the interior of the scope. This again, in view of the nature of the instrument and its intended use, is unacceptable. Accordingly, the present invention proposed a unique means for protection of both the scope and the grasping head 44 during positioning of the instrument, particularly as it passes through the working channel of the scope, without in any manner interfering with the desired and normal operation of the grasping claws 46.
More particularly, the closure sleeve 56 is surrounded by an elongate sheath 72 with the distal end portion 74 thereof extendable to overlie and enclose the projecting forward tip portions 48 of the collapsed claws 46 as best illustrated in FIGS. 2 and 10. Noting FIG. 10 in particular, the internal diameter of the sheath 72 is greater than the external diameter of the closure sleeve 56 for free sliding movement therebetween. As such, the internal diameter of the distal end portion 74 of the sheath 72 is capable of enveloping or completely enclosing the claws 46 while accommodating the tip portions, slightly spread even in the collapsed position thereof, without a compression of these tip portions as might effect an undesirable wedging or locking thereof. Incidentally, in reference to the sheath 72 completely enclosing the claws, this is intended to describe the position of the sheath when the open leading or distal end 74 thereof is positioned sufficiently beyond the claw tips 48 so as to avoid any possibility of engagement of these tips with the scope as the instrument passes through the working channel of the scope.
The proximal end of the sheath 72 is received longitudinally within and mounted for longitudinal reciprocation by an elongate slide 76.
The slide 76 includes an elongate channel-shaped base or base housing 78. The slide base 78 is approximately twice the length of the handle 22 and is defined by a bottom wall 80 and opposed side walls 82. The rear approximately one half of the slide base 78 is telescopically slidable within the handle 22 through the open forward end 26 thereof. Within the handle 22, and as best noted in FIG. 8, the bottom wall 80 and side walls 82 of the slide base or housing 78 are of a size for intimate sliding engagement with the side walls 38 and bottom wall of the handle 22 immediately inward thereof and in surrounding relation to the control knob body 62. The upper edges of the opposed side walls 82 of the slide housing slidably engage the overlying shoulders 40 defined by the top wall 34 of the handle 22 to the opposite sides of the longitudinal slot 32 therein. The slotted top wall 34 of the handle 22 thus retains both the slide 76 and the control knob 58 for longitudinal reciprocation relative to the handle 22.
The slide 76, immediately forward of the open forward end 26 of the handle 22, includes a top panel 84 welded or otherwise secured between the top edges of the side walls 82 for closing the open top of the slide channel. The panel 84 terminates in a forwardly extending externally threaded neck portion 86 position generally coaxial with the hollow interior of the slide housing 78.
The sheath 72, immediately forward of the neck portion 86, has a sheath seat 88 thereabout and adhesively or otherwise positively affixed thereto. The sheath seat 88 includes a conically configured forwardly directed camming surface 90. The sheath seat 88, and hence the sheath 72 itself, is affixed to the forward end of the neck or neck portion 86 by a retainer or a retaining collar 92 which is received over the sheath seat 88 and is threaded or otherwise fitted onto the neck 86 to rearwardly engage and clamp the seat 88 against the leading end of the neck 86. This is effected by an internal conical bearing surface 94 on the retainer 92 which engages against the seat surface 90 for a clamping bias of the seat 88 against the leading end of the neck as well as toward the sheath 72 to enhance the engagement therebetween. When thus mounted, movement of the slide 76 effects a simultaneous movement of the sheath 72.
The actual manipulation of the slide 76, and hence the sheath 72, is effected by a finger-manipulating plate 96 integral with and projecting laterally from the inner end of the top panel 84. This finger plate 96 is wider than the slide housing 78 and extends vertically along the side walls 82 immediately outward thereof as will be best noted in FIG. 1.
The inner or proximal end of the slide 76 includes an end wall 98 with a central slot 100 therethrough for the accommodation of the cable or shaft 42. The slot 100 extends from the bottom wall 80 through the top of the end wall 98, to define a pair of laterally spaced end wall sections 102. In the rearmost retracted position of the slide 76, and hence the sheath 72, as illustrated in FIGS. 3, 4, 6, 7, the rear end wall 98 of the slide 76 abuts against the inner end of the rear plug cap 30.
An elongate stop member 104 is fixed within the rear portion of the slide housing 78 and extends forwardly from the rear wall 98, terminating in a forward abutment face or end 106 which in turn constitutes a stop against which the control knob 58 engages in its rearmost retracted position. The member 104 has a full length upwardly directed channel 108 defined therein and in generally coaxial alignment with the slide 76 and handle 22 for the free accommodation of both the cable 42 and closure sleeve 56 for free relative movement therebetween.
The abutment face 106 of the stop member 104, when the slide 76 is fully retracted, defines the rearmost position of the control knob 58 as it retracts. This in turn defines the retracted position of the closure sleeve 56. This relationship will best be noted in FIGS. 4 and 7. As previously indicated, the forwardmost position of the control knob 58 and hence the closure sleeve 56 is defined by abutment of the control knob against the forward cross bar member 36 of the top wall 34, note FIGS. 3 and 6.
The forwardmost position of the protective sheath 72, enclosing both the closure sleeve and the collapsed although protruding claw tip portions 48, is defined by engagement of the forward abutment end 106 of the stop member 104 against the control knob 58 as it in turn is engaged against the cross member 36, note FIGS. 2 and 5.
Because of the relationship between the stop member 104 and the control knob 58, a forward extension of the sheath so as to enclose the grasping head 44 will, through engagement of the stop member abutment face 106 with the control knob 58, always insure that the closure sleeve is in its forwardmost claw-collapsing position when the sheath is extended. Similarly, retraction of the closure sleeve 56 through a rearward movement of the control knob 58 will, by engagement against the abutment face 106 of the stop member 104, simultaneously effect a rearward movement of the sheath for exposure of both the forward portion of the closure sleeve 56 and the grasping head 44 as the claws move to the open position. In actual use, the manipulation of the components will normally involve sequential operation. More particularly, the instrument, prior to use, will be oriented with both the slide 76 and the control knob 58 in their forwardmost positions, thus both collapsing the grasping head 44 and completely enclosing the claws, note in particular the sectional detail of FIG. 10. As illustrated in this figure, the extended closure sleeve 56 terminates short of the leading end portions of the claws 46 whereby the claws 46 are collapsed into general axial alignment with the closure sleeve 56 without such a compressing and interlocking of the leading tips 48 as might preclude free resilient opening of the claws upon retraction of the closure sleeve. The leading portion 74 of the sheath 72 is positioned with the leading end beyond the collapsed grasping claws 46 so as to completely envelope and enclose the claws. As will be appreciated, the internal diameter of the sheath 72, which is greater than the external diameter of the closure sleeve 56, is also sufficient so as to freely move over the collapsed claws 46 without exerting an additional collapsing or compressing force thereon such as might interfere with their operational control solely by the closure sleeve 56.
When positioned as detailed in FIG. 10, the leading end of the forceps is protected for non-damaging introduction through the working channel 110 of a ureteroscope 112 or the like as schematically illustrated in FIG. 10. The enclosing of the collapsed yet freely expandable claws by the forwardly projecting sheath protects both the tips of the forceps and the working channel of the scope, thus providing a significant dual function.
Once the sheath-protected distal end of the forceps protrudes from the body-received inner end of the scope 112, the sheath is held stationary and the closure sleeve and claws are advanced to expose both the claw-collapsing closure sleeve and the leading tip ends of the collapsed claws. The claws 46 can then be opened and closed through a manipulation of the closure sleeve 56 and without varying the axial position of the grasping head relative to the handle 22, the end of the sheath, or the scope's objective lens (not shown). This helps the user of the device to capture the target, whether a stone, stent, or tissue clump. Further, with the opening and closing of the claws 46 accomplished by the closure sleeve 56 sliding longitudinally forward and rearward relative thereto about the claw-mounting cable or shaft, the claws 46 are capable of closing down on and around the target object without also simultaneously pulling away from the target object, a highly desirable feature in the environment of the invention.
With reference to FIGS. 11 and 12, the present invention also contemplates an embodiment wherein the slide 78, and hence the sheath 72, is releasably locked in its rearmost retracted position. This is effected by a pair of spring fingers 114, preferable integrally formed with the end plug closure 30 and projecting inwardly therefrom into the handle slot 32 in the upper wall 34. The fingers 114 will preferably be substantially coplanar with the upper wall 34 and adjacent the opposed edges of the slot. The inner ends of the fingers 114 each include a depending tip 116 projecting into the handle chamber 24 below the upper wall 34 and into the path of rearward movement of the rear end wall 98 of the slide body 80.
The rear wall 98 and in particular the opposed vertical portions 102 thereof to the opposite sides of the central slot 100, upon a retraction of the slide 76, snap behind and are confined by the finger tips 116. This snap-engagement is facilitated by a resilient flexing of the fingers 114 and round corners on both the tips 116 and end wall 98. It is preferred that the wall-accommodating space between the tips 116 and the forward end of the closure plug 30 be such as to closely receive the end wall 98 whereby, when confined, the slide and sheath are fixed until moved by positive manual pressure.
FIGS. 11 and 12 are also of interest in illustrating a modified form of stop member 118 in the nature of a vertically upstanding cylindrical or other shaped projection integral with the bottom wall 80 of the slide housing 78, as opposed to the extended stop member 104 of the first-described embodiment.
FIGS. 13 and 14 illustrate another means for releasably retaining the slide, and hence the sheath affixed thereto, in both its extended and retracted positions within the handle 22. This is achieved by a locating means comprising a projection 120, of rounded or tapered configuration, extending from the outer surface of one of the slide side walls 82, and a pair of depressions or recesses 122 in the inner surface of a corresponding side wall 38 of the handle 22. The depressions 122 are spaced so as to, upon reception of the projection 120, define the two extreme positions of the slide. In order to facilitate movement of the projection into and out of the recesses 122, as well as along the handle therebetween, the side wall 82, to the opposite sides of the projection 120 can be provided with vertical slots 124 whereby that portion of the wall containing the projection 120 will have an added degree of flexure.
Yet another variation is illustrated in the detail of FIG. 15 wherein both of the opposed side walls 82 of the slide 76 include projections 126 for selective reception within a pair of recesses 128 in the side walls 38 of the handle 22. In this embodiment, the projections 126 move between a position forward of the forward end 26 of the handle and a retracted position, in through the forward end 26 and into releasable locking engagement within the recesses 128. The projection and recess arrangement can, as will be appreciated, constitute a single projection and single cooperating recess, or multiple projections and recesses. Similarly, the projections and recesses, in addition to being located on the side walls, can also, or as an alternative, be located on the cooperating bottom walls of the slide and handle. In each case, in the retracted position of the slide, the rear wall 98 of the slide will preferably abut against the inner end of the end closure plug 30 either with or without the use of the retention or positioning means, as in FIGS. 11-15, for the releasible locking of the slide and sheath in the retracted position.
The rectangular configuration of the handle is significant in facilitating a positive gripping and handling of the device in one hand for ease of manipulation and control with the handle cradled within the palm, the thumb engaged with the control knob 58 and one or two fingers engaged with the push plate 96.
The various components of the forceps are to be formed of appropriate material capable of withstanding standard medical sterilization, for example stainless steel for the closure sleeve, ethylene tetrafluoroethylene plastic for the sheath, and acrylonitrile-butadiene-styrene for the handle and slide. | A grasping forceps including a handle and an elongate cable with resiliently outwardly flared claws at the leading end thereof. The cable is of a fixed length relative to the handle. A closure sleeve surrounds the cable and is selectively manipulated from the handle, for movement to an extended position, relative to the handle, wherein the forward portion of the closure sleeve envelops and inwardly collapses all but the leading end portions of the claws. The closure sleeve in the retracted position, allowing for an outward springing of the claws into grasping position. The closure sleeve is surrounded by a sheath selectively extensible and relative to the handle and moveable to an extended position fully enclosing the closure sleeve and collapsed claws, the sheath projecting slightly forward thereof whereby the claw tips are recessed relative to the forward end of the sheath and are completely protectively enclosed thereby. The handle of the device, as well as the sheath controlling slide are of complementary rectangular configurations. Cooperating releasible interlocking elements can be provided to fix the sheath in the retracted position. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a radiographic installation comprising a film support, transportable from a readiness position into at least one exposure position and back again, with displaceable clamping jaws for the support-mounting of x-ray film cassettes of varying format.
Through the German AS No. 20 44 848 an x-ray spot film device or x-ray cassette changer is known in which an x-ray film cassette is transportable by motor means from a readiness position into an exposure position. In the case of this x-ray spot film device or x-ray cassette changer, voltage dividers are adjusted by the clamping jaws which can be brought to rest against the cassette edges. The adjusted resistance values, together with a constant value for the path specification, are connected with a motor-driven follow-up control for the control of the movement of the cassette carriage from the readiness position into the exposure position. These resistance values can also be connected to an additional follow-up control for the purpose of preadjustment of the collimator. It is a peculiar feature of this construction that the voltage dividers, which convert the sensed cassette dimensions into electrical values, must have an electric connection with the radiographic installation and, in the case of a corresponding control of the collimator, must also have an electric connection with the remaining x-ray examination apparatus. This has as a consequence the fact that the voltage dividers coupled to the clamping jaws must either be rigidly wired with the remaining x-ray examination apparatus, or that they are to be connected to the latter by means of a plug-in connection. Both prevent or obstruct the removal of the film support.
The German patent No. 24 15 410 which corresponds to U.S. Pat. No. 3,986,034 disclose a cassette plate insertable beneath an examination table in which the clamping jaws, during abutment on the cassette edges, adjust a permanent magnet displaceably mounted transversely to the insert direction, via a cable pull in the cassette plate. This permanent magnet activates, depending upon the position of the inserted cassette plate, one of several reed contacts installed in the longitudinally running carriage of the examination table. This reed contact then connects a corresponding resistance in a follow-up control for the collimator and thus adjusts the latter to the sensed cassette dimensions. It is a peculiar feature of this construction that although the cassette plate manages without electric connections and therefore can be readily removed from the examination table, it can, in exchange, be employed only in the case of specific, discrete, matched cassette dimensions.
In order to be able to adjust the collimator also to x-ray film cassettes of a random format, it has become known from the German OS No. 27 44 139 to mount sensors on the frame-shaped longitudinally running carriage remaining in the examination table which, during insertion of an x-ray film cassette clamped on a cassette plate, abut externally on the clamping jaws of the cassette plate and, via a gear, adjust one separate potentiometer each for the width and for the height of the x-ray film cassette. Such sensors must be relatively narrow and long and therefore have the property of readily bending. Thus, either the insert opening of the cassette plate is blocked, or, as a consequence of sliding past the clamping jaws of the cassette plate, erroneous exposures result. Moreover, a considerable fine-mechanical outlay for the transmission of the movement of the sensors to corresponding potentiometers is necessary. Even minor angle changes can lead to clearly measurable resistance changes.
SUMMARY OF THE INVENTION
Accordingly, the object underlying the invention resides in pointing out a way to achieve the advantages of an automatic definition of radiation width and an automatic specification of cassette insertion distance on the basis of sensed cassette dimensions, for x-ray spot film devices, flat diaphragms, and such cassette support plates which, in the case of such examinations in which cassettes are not required, can again be completely removed from the radiographic installation in order to not impair the full freedom of movement of the remaining modules of the x-ray examination apparatus. In addition, this solution is to render possible the utilization of cassettes of random size and is to be simultaneously sturdy and economical.
In the case of a radiographic installation of the type initially cited, accordingly, in accordance with the invention, the film support and the clamping jaws are coupled with transmitters, whereby the transmitters of the clamping jaws in dependence upon the clamping width of each clamping jaw pair, are adjustable in a displacement direction of the film support relative to the film support, and receivers are associated with the transmitters. The receivers are connected with the guides for the film support and, together with an actual value transmitter for representing the actual movement of the film support, are connected to a measured value processing arrangement. In the case of such a design of the radiographic installation, the distances of the transmitters coupled with the clamping jaws from the transmitter coupled with the cassette carrier are proportional to the cassette dimensions read-off at the respective clamping jaws. This is a basic prerequisite for a simple measured value processing. At the same time, the adjustment of the transmitters in displacement direction of the cassette carriage is a prerequisite for further embodiments of the invention.
In a particularly advantageous further development of the invention, the receivers can be light source-photosensor arrangements between which flat, opaque plates as transmitters can be guided. The film support with its clamping jaws can hereby be realized without any electrical connections whatsoever. This has as a consequence the fact that the film base can readily be drawn out, or removed from the x-ray examination apparatus. This can be the case, inter alia, if fluoroscopy is to be carried out and the displaceability of the fluoroscopy installation in the table longitudinal direction is not to be impaired by a film support placed at the foot end or head end of the examination table.
A particularly reliable and simultaneously simple construction of the radiographic installation results if the transmitter, in an expedient embodiment of the invention, is connected with the clamping jaw via a spring-loaded cable line. This leads to a space-saving and simultaneously easy-to-repair construction.
In a particularly expedient further development of the invention, the actual value transmitter for representing the actual positioning movement of the film support can generate a specified number of pulses per increment of distance traveled. This method of construction has as a consequence not only, in conjunction with the linear adjustment of the transmitters in the film support, a linear measured value processing, but also leads to a relatively simple subsequent measured value processing with relatively economical digital components.
In a particularly advantageous embodiment of the invention, the pulses occurring in the interval between the transmitters of the film support and the corresponding clamping jaw, conveyed past one receiver, can be separately counted as an actual value input for the sensed cassette dimension. The thus-counted pulses are a direct measure of the corresponding width, and length, respectively, of the x-ray film cassette. Their pick-up is entirely independent of the speed with which the film support with the three transmitters is conveyed past the receivers. Moreover, in this manner, the actual value transmitter can be employed for the positioning of the film as well as for the measuring of the width and height of the inserted x-ray film cassette, so that the determination of the dimensions of the x-ray film cassette and the corresponding displacement of the cassette carrier (or support) from the readiness position into the exposure position and back again can be carried out by one single pulse transmitter and three measuring elements. It makes no difference whether a servomotor is operated or, in the case of manual adjustment of the film base, the latter is locked in the exposure positions via magnetic brakes.
Further details of the invention shall be explained on the basis of an exemplary embodiment illustrated in the Figures of the accompanying drawings sheets; and other objects, features and advantages will be apparent from this detailed disclosure and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an x-ray examination apparatus comprising an under-table spot film device in an end view; and
FIG. 2 illustrates a schematic representation of the means for coupling the film positioning parts with the transmitters and receivers.
DETAILED DESCRIPTION
In FIG. 1, one recognizes an examination table 1 with a patient support platform 2 with a film support, comprising in the exemplary embodiment a cassette plate 4, insertable in a longitudinally running carriage 3 transportable in a table longitudinal direction. Beneath the longitudinally running carriage of the examination table there is mounted an image intensifier and television camera assembly 8, carried by a mounting frame 5, displaceable in a table longitudinal direction along guide rails 6, 7. The image intensifier television installation 8 is connected via two coupling plates 9, 10, with the longitudinally running carriage 3. Adjacent the examination table 1 a pillar 12, transportable on the floor along a rail 11, can be recognized, which, above the examination table, on a horizontal extension arm 13, supports an x-ray tube 14 with an adjustable collimator 15. The collimator is manually adjustable with the aid of the adjustment knobs 16, 17. These adjustment knobs are, moreover, adjustable via remote-controllable adjustment gears (not illustrated). For this purpose, the collimator 15 is connected via an electric cable 18 with the examination table 1.
FIG. 2 illustrates, in a schematic representation, a part of the frame 19 of the longitudinally running carriage 3 displaceable beneath the patient support platform 2 in the longitudinal direction of the examination table 1. The cassette plate 4 is illustrated in FIG. 2 removed from the longitudinally running carriage. At its four corners it bears rollers 20, 21, 22, 23, with which it is insertable transversely to the examination table 1 into a laterally opening frame section fabricated from U-shaped rails 24, 25 of the longitudinally running carriage 3. Along the cassette plate 4 an endless conveyor belt 26 can be recognized. The conveyor belt is tensioned via two rollers 27, 28, the one of which is driven by a motor 29. The rollers 27, 28, are mounted on the two ends of the left (as viewed in FIG. 2) U-rail 24--greatly shortened for the purpose of clarity--of the longitudinal running carriage 3. The conveyor belt 26 supports a coupling piece 30 into which a tongue 31 of the cassette plate 4 is insertable.
On the shaft of the motor 29 a perforated disk 32 is mounted in a twisting-proof fashion. This perforated disk rotates with its series of perforations moving between the light sources 34, 35 and photoelectric cells 36, 37--mounted on opposite sides of a U-shaped support member 33--of two light source-photocell arrangements 38, 39 which form an actual valve generator. The mutual distance of the two light source arrangements 38, 39 along the path of movement of the perforations amounts to an odd-numbered multiple of one-half the perforation separation distance on the perforated disk 32 so that two separate pulses are generated per perforation in each revolution of disk 32.
On the cassette plate 4 four clamping jaws 40, 41, 42, 43, adjustable in opposite directions in pairs, can be recognized. Via spring-loaded adjusting drives, not further illustrated here, they are pressed against the edges of the inserted x-ray film cassette 44. Along the right side (as viewed in FIG. 2) of the cassette plate 4, somewhat offset in relation to the plane of the cassette plate, there are three reflection sheets or actuators 45, 46, 47. The center one of the three reflection sheets, sheet 46, is rigidly connected with the cassette plate 4 via an angled holder 48. The front reflection sheet 45 in FIG. 2 is mounted, via an offset holder 49, on a clamping jaw 40 of the clamping jaw pair displaceable in the insertion direction of the cassette plate 4. The rear reflection sheet 47 in FIG. 2 is mounted with its holder 50 on a traction cable 52 guided about a deflection (or guide) pulley 51 (mounted on the cassette plate 4). This traction cable 52 at its one end, is secured with the clamping jaw 43 of the clamping jaw pair, displaceable transversely to the insertion direction of the cassette plate 4, and at its other end, is secured to one end of a tension spring 53 whose other end is fixed relative to the cassette plate 4. At a position along the path of movement of these reflection elements 45, 46, 47, there is arranged a light source-photocell or actuator proximity sensing arrangement 54 mounted on the longitudinally running carriage. In the rear portion of FIG. 2, for the purpose of clarification, the radiation field 55 to be delineated, for a partial exposure of the x-ray film cassette 44, is illustrated between the U-rails 24, 25.
The photoelectric cells 36, 37, of the two light barriers associated with perforated disk 32 , as well as the photoelectric cell 56 of the light source-detector arrangement 54, associated with the reflection foils 45, 46, 47, are connected to a measured value processing arrangement 57. The latter, in turn, is connected with the motor 29 for effecting the displacement of the cassette plate 4, and with the collimator 15.
As long as the cassette plate 4 is removed from the frame-shaped longitudinally running carriage 3, the latter is capable of being irradiated in a shadow-free fashion. This means that it can be connected, as frame 19, with the image intensifier television installation 8, disposed therebelow. In this case, it also does not obstruct the displaceability of the image intensifier television installation in the longitudinal direction of the examination table 1. If a radiograph is to be prepared with the aid of an x-ray film cassette 44, the cassette plate 4 can be inserted in the U-rails 24, 25 of the longitudinally running carriage 3 and can thus be coupled by means of tongue 31 with the coupling piece 30 of the coveyor belt 26. Now an x-ray film cassette 44 of a suitable size can be inserted between the clamping jaws 40, 41, 42, 43. After insertion of the x-ray film cassette 44, the clamping jaws 40, 41, 42, 43, in a known fashion, rest against the end faces of the x-ray film cassette and center the latter relative to the center of the cassette plate 4. Now the distance of the reflection elements 45, 47, connected with the two adjustable clamping jaws 40, 43, relative to the reflection element 46, rigidly mounted on the cassette plate 4, corresponds to the height, and the width, respectively of the x-ray film cassette.
If, during the examination with the image intensifier television installation 8, a finding appears which is to be retained, the motor 29 for the transport of the cassette plate 4 can be switched on in a fashion not further illustrated here. By means of said motor the conveyor belt 26 with the coupling piece 30 and the cassette plate coupled with the conveyor belt via the inserted tongue 31, is driven into the exposure position. The two light source-detector assemblies 38, 39, associated with the circular perforated disk 32, count the holes of the perforated disk 32 conveyed past them. Their number is--as has already been described in detail in the German Patent 24 40 146 and in the corresponding U.S. Pat. No. 4,049,967--a measure of the amount and of the direction of the movement of the cassette plate 4. During driving of the cassette plate the reflection elements 45, 46, 47, at the side of the cassette plate, successively intersect the light path of the light source-detector assembly 54. The photoelectric cell 56 of this light source-detector assembly 54 thus generates one pulse which is further transmitted to the measured value processing arrangement 57. The pulses generated via the perforated disk 32, arriving during the time interval between the passing of the reflection foil 45, 47, connected with one clamping jaw 40, 43, respectively, and the reflection foil 46, rigidly connected with the cassette plate 4, are counted in a respectively separate counter of the measured value processing arrangement 57. The counts provide a measure of the length, and of the width, respectively of the x-ray film cassette 44, clamped on the cassette plate 4, and can be utilized by the measured value processing arrangement for the purpose of control of the entry of the cassette plate into the exposure position.
Because the path distance, respectively corresponding to one pulse, is exactly the same in all three instances, the 1:2 geared-down (or reduced) pulses, counted for the cassette dimensions, can be directly subtracted from or added to the specified number of pulses corresponding to the normal adjustment path of the cassette plate for nondivided exposures, in order to switch off the servo motor in the two thus calculated exposure positions in the case of a doubly subdivided exposure. Based on the separately stored pulses, corresponding to the cassette dimensions, a follow-up control can be effected for the adjustment of the collimator 15. In the same manner as, in the exemplary embodiment, the adjustment of the cassette plate 4 transversely to the examination table 1 is illustrated, also the longitudinally running carriage 3, or a portion of the same, can be adjusted with the U-rails 24, 25 on the basis of the read-off cassette dimensions for the purpose of accommodating film subdivision in the table longitudinal direction. It is a particular advantage of this method of construction that only one motor 29, three light source-detector units 38, 39, 54, and three reflection elements 45, 46, 47, are sufficient in order to achieve a fully automatic sensing of the cassette dimensions and control of the advance of the cassette plate into the exposure position. Instead of the reflection elements, permanent magnets can likewise also be utilized and, instead of the light source-detector units, reed contacts or coils can likewise also be utilized.
It will be apparent that many modifications and variations may be effected without departing from the scope of the novel concepts and teachings of the present invention. | In an exemplary embodiment displaceable clamping jaws mount x-ray film cassettes of varying format for movement into the exposure position. In the case of such x-ray cassette changers it is necessary that the width-definition of the cone of rays corresponds to the dimensions of the inserted x-ray film cassette. The film support, in the case of fluoroscopy, should be capable of being removed from the examination apparatus without difficulties. For this purpose, the disclosure provides that the film support and the clamping jaws are coupled with transmitters which assume positions with respect to a displacement direction of the film support in dependence on the clamping positions of the respective pairs of clamping jaws. Associated with the transmitters are receivers which, together with an actual value transmitter responsive to movement of the film support, are connected to a measured value processing arrangement. The disclosure radiographic installation is particularly suited for utilization with under-table spot film devices. | 0 |
BACKGROUND OF THE INVENTION
This invention relates generally to machine tools and in particular to a boring bar adjusting apparatus for automatically measuring the diameter of a hole produced by the boring in the spindle of the machine tool and automatically adjusting the boring bar if the hole is not within tolerances.
Many of the boring operations completed on workpieces produced in manufacturing facilities are performed by computer numerically controlled (CNC) machining centers. Often, such machining centers include an automatic tool changer which transfers tools between the machine tool storage magazine and the machine tool spindle without the need for manual intervention. Such automatic tool changing machine centers not only increase production, but also reduce direct labor costs.
To achieve relatively high production, while still affording the flexibility of manufacturing different types of parts, manufacturing cells, and flexible manufacturing systems have been developed utilizing machining centers that are interconnected by way of a workpiece transfer or shuttle mechanism. In such manufacturing cells and flexible manufacturing systems, once the part has been machined, the part is usually inspected to assure that the part meets manufacturing tolerances. Such inspection can be accomplished at the machine tool, by way of a spindle probe, but more often, part inspection generally occurs at a separate inspection station, which may include one or more automatic inspection devices. If, during the inspection process, the part does not meet manufacturing tolerance, such as may occur when a workpiece bore is slightly undersized, by virtue of having been machined by a worn cutting tool, then the part is diverted for subsequent machining. In large manufacturing facilities the diversion of parts to be remachined often creates a logistics difficulty which may seriously impede part production.
In an effort to overcome this difficulty, the present invention is directed to an automatic boring bar adjustment apparatus for a machine tool. The invention provides for measuring the hole produced by the boring bar and automatically adjusting the boring bar to compensate for any error in the diameter of the hole and then reboring the hole to the proper diameter.
BRIEF SUMMARY OF THE INVENTION
In accordance with the preferred embodiment of the invention, there is provided a boring bar adjusting apparatus for automatically measuring the workpiece bore size produced by the boring bar and adjusting the boring bar, if necessary. The invention includes a measuring gauge or head mounted in a tool holder stored in the machine tool storage magazine for transfer to the machine tool spindle by an automatic tool changer. When the workpiece bore is measured by the measuring head and is found to be undersize, the measuring head is exchanged with a boring bar mounted in a tool holder normally stored at the machine tool storage magazine. The boring bar carries a cutting insert that is adjustable to vary the size of the bore cut by the cutting insert. Upon transfer of the boring bar to the machine tool spindle, an actuating mechanism, carried by the machine tool, engages the boring bar in the spindle to adjust the cutting tool to change the diameter of the bore produced by it. The actuating mechanism is controlled by a numerical control circuit in accordance with the difference between actual bore size as measured by the measuring head and the desired bore size so that the boring bar can be set to accurately machine the workpiece bore.
It is an object of the present invention to provide an automatic boring bar adjusting apparatus for measuring the workpiece bore size and automatically adjusting the size of the bore in response to the measurement. A measuring gauge is mounted in a tool holder stored in the tool storage magazine for automatic transfer to the spindle upon the completion of a boring operation to measure the diameter of the bore. After the measurement has been completed, the boring bar used to bore the hole is removed from the tool storage magazine and exchanged with the measuring gauge so that it can be automatically adjusted to produce the required diameter bore in the workpiece.
Other objects and advantages of the present invention will become apparent from the following specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself, however, both as to organization and method of operation, together with further objects and advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a front fragmentary view in elevation of the spindle head of a machine tool illustrating the boring bar of the present invention mounted in the spindle therein;
FIG. 2 is a front fragmentary view in elevation of the spindle head of a machine tool showing the measuring head of the present invention mounted therein;
FIG. 3 is a fragmentary view partially in section and viewed from the plane of the line 3--3 of FIG. 1 illustrating the details of the boring bar and actuating mechanism therefor;
FIG. 4 is a detail view partially in section of the boring bar of FIG. 3 showing the engagement of the boring bar actuating mechanism with the boring bar;
FIG. 5 is a fragmentary view partially in section and viewed from the plane of the line 5--5 of FIG. 2 illustrating the details of the measuring head of the present invention;
FIG. 6 is a detail view showing the measuring head of FIG. 5 and illustrating the engagement of the measuring head connector with the measuring head jack on the machine tool;
FIG. 7 is a front fragmentary view of the machine tool spindle head illustrating both the measuring gauge and boring means in phantom to depict how each is positioned in the spindle;
FIG. 8 is a plan view of the machine tool spindle head of FIG. 1, 2 and 7 illustrating the details of the actuating mechanism which sets the cutting insert carried by the boring bar;
FIG. 9 is a fragmentary view partially in section and viewed from the Plane of the line 9--9 of FIG. 8 illustrating additional details of the actuating mechanism;
FIG. 10 is a cutaway detail view of the machine tool spindle head illustrating the connection of the measuring head jack on the machine tool to a numerical control circuit;
FIG. 11 is an enlarged, detail view of the boring bar of FIG. 5 showing the cutting insert carried thereby at its radially inward most position; and
FIG. 12 is an enlarged fragmentary view partially in section of the boring bar of FIG. 5 showing the cutting insert carried thereby at a radially outward position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, FIG. 1, 2 and 7 illustrate a partial frontal view of the spindle head 10 carried by a machine tool. Generally the machine tool which carries spindle head 10 is an automatic-tool changing such as are well known in the art. Rotatably journaled in the spindle head 10 is a spindle 12 driven by a motor which is controlled by the numerical control circuit. Such controls are well known in the art and are capable of positioning the spindle at a precise angular orientation.
Prior to a machining operation, the cutting tool then in the spindle is exchanged by the tool changer with the desired cutting tool, such as a boring tool and the machining operation is performed by relating the spindle while moving it axially to feed the tool into the workpiece. Upon completion of a cutting operation, the tool in the spindle 12 is replaced with another tool so that the next cutting operation can be performed.
Although cutting tools are manufactured from extremely hard alloys, boring tool wear is nevertheless inevitable. As the boring tool wears, the outer diameter of the boring tool decreases and as a consequence, the workpiece bore cut becomes undersize. If the boring tool wear is substantial, the workpiece bore size may fall outside of manufacturing tolerances. This may necessitate part rework. Often, the part must be transferred to another machine to properly size the workpiece bore.
In order to avoid such error, the present invention provides an automatic boring bar adjusting apparatus comprised of a measuring head 14 (illustrated in FIG. 5), a boring bar 16 having a radially adjustable cutting insert 105 (illustrated in FIG. 3), and actuating means 20 (illustrated in FIG. 3) for adjusting the boring bar in response to the bore size measured by the measuring gauge so that the boring bar 16, when driven by the spindle 12, forms the required hole with precision.
Referring to FIG. 5, the measuring head 14 includes a multiple diameter linear variable differential transformer (LVDT) 22 which is mounted at one end of a shaft 24 by a recoil shock mount (not shown) located within the transformer 22. The opposite end of shaft 24 is secured to a tool holder 26 to enable the assembly to be stored in the tool storage magazine and to be received by the spindle 12. The tool holder 26 is conventional in its construction and is provided with an outer annular groove 28 in its periphery, to enable the tool holder 26 to be gripped by the automatic tool changer (not shown) of the machine tool.
The linear variable differential transformer 22 is electrically connected to cable 30 (shown by a broken line), which feeds into a junction box 32 mounted to the forward face of its associated tool holder by a right angle mounting bracket 34. Therefore, the junction box 32 extends radially outwardly from the outer periphery of the tool holder 26. Extending rearwardly from the junction box 32 is a connector 36 electrically connected by cable 30 to the transformer 22. The connector 36 is adapted to engage a connecting jack 38.
Connecting jack 38 is mounted to the end of a conduit stub 40 which is slidably disposed in a recess 42 in the machine tool spindle head so as to be parallel to the spindle 12. The conduit stub 40 is guided within the recess 42 by a nut 44 threaded onto the rearward (rightward) end of the conduit stub and a second nut 46 threaded about the rearward end of a collar 48 which has its forward end threaded into the end of the conduit stub 40. Additional guiding for the conduit stub 40 is provided by a hollow shaft 52 extending rearwardly from the collar 48 into a recess 54 coaxial to, and in communication with the recess 42. The conduit stub 40, the collar 48 and the hollow shaft 52 are all in communication with one another so that a connecting cable 55 extends therethrough for connection to the jack 38. As illustrated in FIG. 10, the cable 55 couples the jack 38 to a numerical control circuit 58 which is conventional and of well known construction.
Returning to FIG. 5, a yoke 60 mechanically links the jack 38 on the end of the conduit stub 40 to the end of a shaft 62 of a piston and cylinder mechanism 64 which, is mounted on the top of the machine tool spindle head 10. When piston and cylinder mechanism 64 is actuated, the shaft 62 of the cylinder is urged outwardly to move the jack 38 into mating engagement with connector 36 to effect electrical connection therewith in the manner illustrated in FIG. 6.
Referring now to FIG. 7, before the connector 36 of the measuring head can be mated with jack 38, the connector must be axially aligned with the jack. Such alignment is accomplished by the control which stops the spindle rotation at the particular angular orientation in which the connector 36 aligns with jack 38.
Once jack 38 is engaged with plug 36 as described, the transformer 22 of the measuring head 14 is connected to the numerical control circuit 58 of FIG. 10. Upon connection to the transformer 22, the numerical control circuit 58 of FIG. 10 operates to determine the workpiece bore size in accordance with the output signal of the transformer 22. The numerical control circuit 58 compares the actual workpiece bore size to the desired bore size which is supplied to the numerical control circuit by way of a command generated by the machine tool control. If the numerical control circuit 58 determines that the actual bore size is too small, the boring bar 16 of FIG. 3 is automatically adjusted to produce the required diameter bore.
As shown in FIG. 3, the boring bar 16 comprises a head 68 which is mounted in a tool holder 70. The tool holder 70, like tool holder 28, is conventional in construction and is adapted to be handled by an automatic tool change mechanism. The head 68 of the boring bar 16 has a central recess 74 which receives a rod 75 that extends forwardly (leftwardly) from the recess 74 and out beyond the end of the head 68. Threads 76 are formed on the rearward end of the rod 75 for engagement with the threaded bore a collar 78 that is journalled in the head 68 for rotation about an axis coaxial with the axis of rod 75. The forward end of collar 78 has an integral bevel gear 79 in meshing engagement with a bevel gear 80 on a stub shaft 82 journaled within an extension housing 83 that projects radially from the head 68. The upper end of stub shaft 82 is provided with an integral bevel gear 84 in meshing engagement with a bevel gear 86 integrally formed on a drive shaft 88. The drive shaft 88 is journaled in the projecting extension housing 83 so as to be parallel to the axis of rod 75.
Upon rotation of drive shaft 88, the bevel gear 86 thereon rotates the stub shaft 82 which in turn drives the collar 78. As collar 78 rotates relative to the rod 75, the latter is threaded out from or into the head 68, depending on the direction of rotation of collar 78. The rod 75 is biased forwardly by a spring 90 interposed between the rearward end of rod 75 and the wall 92 of a recess 93 in the tool holder 70 that is in communication with recess 74 in head 68.
Referring now to FIGS. 3, 11 and 12, the rod 75 disposed through the central bore of the boring bar head 68 is provided with a notch 96 having an inclined wall that is in communication with a radially disposed passageway 98 in the boring bar head 68. An adjusting pin 100 is disposed in the passageway 98 so as to be interposed between the notch 98 and the inner edge of a cutting tool insert-holding cartridge 103 that is seated in a pocket 103a in the outer periphery of the head 68 and is cantilevered at its rearward end to the boring bar head 68 by a bolt 104 threaded radially inwardly into the boring bar head. The cartridge 103 is conventional in its construction and carries a cutting tool insert 105 which performs a cutting operation upon rotation of the boring bar head 68.
When rod 75 is shifted inwardly or rightwardly as viewed in FIG. 12, upon rotation of the drive shaft 88, the pin 100 is urged radially outwardly by the inclined surface of the notch 96 in the rod 75. Such movement of the pin 100 against the cartridge 103 forces the cutting insert 105 radially outwardly for increasing the cutting insert orbit to correspondingly increase the diameter of the bore made thereby. Thus, by regulating the axial position of rod 75, the orbit of insert 105 can be controlled accordingly.
The details of the actuating mechanism 20 that serves to drive the shaft 88 which in turn causes the axial movement of rod 75 to vary the orbit of the cutting insert may best be appreciated by reference to FIGS. 3, 8 and 9. Referring to FIG. 3, a drive member 110 is journaled through the spindle head 10 into the yoke 60 so as to be parallel to but offset from the spindle 12. The rearward end of the drive member 110 has splines 112 which engage the splines on the central bore of a gear 113. The splined engagement of drive member 110 with gear 113 permits the drive member 110 to be shifted axially relative to the gear 113 without interrupting the driving engagement therebetween. The gear 113 engages the teeth of a gear rack 114 slidably mounted on a set of rack ways and retained thereon by retainers 115a and 115b secured to the spindle head by bolts 118. The rack and the rack ways are perpendicular to the axis of rotation of gear 113 and drive member 110. Referring now to FIGS. 8 and 9 jointly, a cylinder 120, is secured to the spindle head 10 by bolts 122 (FIG. 8) and has its shaft 124 threaded into one end of the rack 114. Cylinder 120 is controlled by numerical control circuit 58 (FIG. 10) and upon actuation of the cylinder 120 by the numerical control circuit 58, the cylinder reciprocates the rack 114 to impart a rotary motion to the gear 113 and hence to the drive member 110.
The forward end of the drive member 110, as shown in FIG. 3, extending beyond yoke 60 is provided with a drive tang 128 which is complementary to the drive slot 130 in the rearward end of drive member 88 that is exposed through an opening in the housing 83. As shown in FIG. 4, when cylinder 64 is actuated to displace its shaft 62 outwardly, the yoke 60 shifts the drive member 110 outwardly from the spindle head 10 until a shoulder 134 on the forward end of the drive member 110 abuts the drive shaft 88 and the drive tang 128 mates with the drive slot 130. Once the drive tang 128 of member 110 mates with the drive slot 130, a torque is imparted by drive member 110 to the drive shaft 88 upon axial movement of the rack 114 by the cylinder 120 to appropriately set the radial outward displacement of the cartridge 103 which carries the cutting insert 105 so as to adjust the orbit of the cutting insert 105. The yoke 60 is fixed to both the drive member 110 and its drive tong 128 as well as to the conduit stub 40 and the electrical jack 38 so that actuation of the piston and cylinder mechanism will move both the jack 38 and the drive tang 128. However, as shown in FIGS. 1 and 2, the drive tang 128 is displaced from the jack 38 on the yoke 60.
Before the drive tang 128 on the drive member can be mated with the drive slot 130 on the drive shaft, the drive tang and drive slot must be in axial alignment with one another. As with the measuring head 14 of FIG. 1, such alignment is accomplished by the control stopping the spindle rotation at a particular angular orientation which brings the drive shaft 88 into axial alignment with the member 110. Thus, one angular orientation of the spindle aligns the drive slot 130 with the drive tong 128 and a second angular orientation of the spindle aligns the connector 36 of the measuring head 14 into alignment with the jack 38.
It may be desirable in certain instances to manually set the cartridge radial displacement and hence, the cutting insert orbit. To this end, the forward end of drive shaft 88 extends forwardly beyond the housing 83 and is squared at 140 to receive a crank (not shown) so that the drive shaft 88 can be manually rotated to rotate shaft 82 and collar 78 to axially shift rod 75 thereby adjusting the radial outward displacement of the insert 105.
During normal machine tool operation, the actuation of the boring bar 16, by the axial movement of rack 114 to produce the rotation of drive member 110 is controlled automatically by the numerical control circuit 58. Upon transfer of the measuring head 14 to the machine tool spindle 12 and movement of the transformer 22 into the workpiece bore, the numerical control circuit 58, which is responsive to the transformer 22 output signal, determines and records the difference between the actual bore size and the desired bore size. If the workpiece bore is too small, the boring bar 16 is transferred to the spindle and the drive member 110 of the actuating means 20 engages the boring bar 16 and rack 114 is shifted by cylinder 120 under control of the numerical control circuit 58 to set the cutting insert orbit. As may now be appreciated from the foregoing description of the boring bar adjusting mechanism of the present invention, the proper sizing of the workpiece bore may be completed automatically by the same machine tool in consecutive operation, thereby avoiding the need to transfer the workpiece to complete any part rework that may become necessary.
What has been disclosed is an automatic boring bar adjusting apparatus for a numerically controlled machine tool or the like which enables the bore of a workpiece to be measured and precisely sized automatically in consecutive operations without the need for manual intervention.
While only certain preferred features of the invention have been shown by way of illustration, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | A boring bar adjusting mechanism for automatically correcting an offsize boring cutter. The mechanism includes a measuring gauge and an adjustable boring bar, each mounted in separate tool holders and each stored in the tool storage magazine. The measuring gauge is transferred to the spindle by the machine tool transfer mechanism after a conventional boring operation is completed to measure the work-piece bore. If the bore is inaccurate, the measuring gauge is removed and the boring bar, is loaded into the spindle. The cutting element of the boring bar is adjusted automatically by an adjusting mechanism in response to the bore size measured by the measuring head so that it will machine an accurate bore. | 8 |
BACKGROUND OF INVENTION
The present invention relates generally to hybrid electric automotive vehicles, and more specifically, to monitoring the state of charge of the batteries of the hybrid electric vehicle.
Automotive vehicles with internal combustion engines are typically provided with both a starter motor and alternator. In recent years, a combined alternator and starter motor has been proposed. Such systems have a rotor mounted directly to the crankshaft of the engine and a stator sandwiched between the engine block and the bell housing of the transmission. During initial startup of the vehicle, the starter/generator functions as a starter. While functioning as a starter, the starter/generator rotates the crankshaft of the engine while the cylinders are fired.
After the engine is started, the starter/generator is used as a generator to charge the electrical system of the vehicle.
In foreseeable automotive applications, the engine may be shut down during stops (e.g., red lights). When the accelerator is depressed, the starter/generator starts the motor and the engine will resume firing. Thus, many startups may occur over the course of a trip.
Electrical energy from the 42 volt battery of the vehicle is used to turn the starter/generator which in turn is used to start the motor. Consequently, it is important to maintain the battery so that a certain state of charge is provided to allow the battery to provide enough power to the starter/generator to start the engine. Known systems include ammeters to show the charging of the battery but do not provide an indication as to the capacity of the battery to energize a starting component such as the starter/generator. Also, other factors such as the outside temperature of the vehicle are also not considered in such determinations.
It would therefore be desirable to provide a battery charge monitor to provide an indication to the vehicle operator that the battery may not have sufficient charge or capacity to power the starter/generator to start the engine.
SUMMARY OF INVENTION
The present invention provides a way in which to notify vehicle operators as to the state of the battery. The notification is preferably provided early enough to allow changes to be made so that the vehicle will have enough power to start.
In one aspect of the invention, a method of indicating for a battery of an automotive vehicle comprising monitoring a state of charge of the battery, monitoring a temperature outside of the vehicle, comparing the state of charge to a predetermined state of charge, the predetermined state of charge being a function of the temperature, and generating an indicator when the state of charge reached the predetermined state of charge.
In a further aspect of the invention, a system for an automotive vehicle has a temperature sensor generating a temperature signal indicative of the temperature outside the vehicle and a battery. A battery controller is coupled to the temperature sensor and the battery. The controller monitors a state of charge of the battery and compares the state of charge to a predetermined state of charge. The predetermined state of charge is a function of the temperature. The controller generates an indicator when the state of charge reaches the predetermined state of charge.
One advantage is that the indicator may be provided to the operator in time so that an evasive action may be performed to prevent the state of charge or the battery health to degrade to a point where the battery cannot provide enough power to start the vehicle.
Other advantages and features of the present invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic view of an automotive vehicle having a starter/generator system according to the present invention.
FIG. 2 is a more detailed schematic view of the engine accessory assembly of FIG. 1 .
FIG. 3 is a flowchart illustrating the operation of the present invention.
DETAILED DESCRIPTION
The present invention is described with respect to a particular configuration of a starter/generator relative to a hybrid electric vehicle. However, the teachings of the present invention may be applied to various type of vehicles have battery powered electrical systems.
Referring now to FIG. 1, an automotive vehicle 10 is illustrated having an internal combustion engine 12 having cylinders 14 with pistons 16 located therein. Each cylinder 14 is coupled to a fuel pump 18 through a fuel injector (not shown) or other fuel delivery system. Each cylinder 14 also has a spark plug 20 or other ignition source coupled to a powertrain control unit. A powertrain control unit 22 controls the ignition timing and fuel pump operation 18 in a conventional manner subject to the improvements of the present invention.
Engine 12 is coupled to a transmission 26 . Transmission 26 may be automatic, manual or continuously variable. Transmission 26 is coupled to a differential 28 to drive an axle 30 to provide power to wheels 32 . Of course, the present invention is also applicable to four wheel drive systems in which all of the wheels 32 are driven. A starter/generator system 40 that includes a starter/generator 42 and its associated control electronics is coupled to engine 12 . In the present invention, starter/generator 42 is positioned between a housing 44 of transmission 26 and the engine 12 . Of course, those skilled in the art will recognize other positions are available including but not limited to belt driven types. Starter/generator 42 has a stator fixedly attached to bell housing 44 and a rotor 48 coupled to a crankshaft 50 of engine 12 . A clutch 52 is used to engage and disengage engine 12 from transmission 26 . As will be further described below, starter/generator 42 is used as a starter during engine startup and as an alternator to supply power to recharge the batteries of the vehicle and to supply electrical loads. Clutch 52 allows starter/generator 42 to start the engine prior to engagement of the transmission.
Starter/generator system 40 has a system controller 54 that is coupled to powertrain control unit 22 and to a power inverter 56 . In practice, the power inverter 56 and system controller 54 may be contained in a single package. The inverter 56 is used to convert DC power to AC power in the motoring mode and AC power to DC power in power generation mode as will be further described below.
Power inverter 56 is coupled to an energy storage device 58 such as an ultra capacitor, a first DC to DC converter 60 , and a second DC to DC converter 62 . DC to DC converter 60 is coupled to a 42 volt battery 64 . DC to DC converter 62 is coupled to a 12 volt battery 66 . Of course, the actual battery voltage is dependent on the particular system to which it is attached.
Referring now to FIG. 2, a more detailed block diagrammatic view of the system 40 is illustrated in further detail. Both a 42 volt battery 64 and a 12 volt battery 66 from FIG. 1 are included. Also, the DC power source may be the starter/alternator 42 illustrated in FIG. 1 . The starter/alternator 42 is coupled to the 42 volt bus 70 through a regulator 72 . Of course, other loads 74 A, 74 B, and 74 C are also coupled to bus 70 .
Battery controller 54 is coupled to 42 volt battery 64 through a voltage monitor 76 and a current monitor 78 . By monitoring the battery voltage and current through voltage monitor 76 and current monitor 78 , the state of charge of the 42 volt battery 64 may be determined.
Battery controller 54 is also coupled to an indicator 80 . Indicator 80 may comprise an audible indicator, a visual indicator, or a combination of the two. Indicator 80 may also be located remotely from the vehicle and may comprise a cell phone, page or e-mail device. For these devices a vehicle communications telematic system 82 is coupled to battery controller 54 . Vehicle communication telematic system 82 may couple information to a cell tower 84 or a satellite 86 . The telematic system 82 may also be coupled to the vehicle global positioning system 88 .
Battery controller 54 may also be coupled to a temperature sensor 90 for determining the outside temperature at the exterior of the vehicle. By knowing the exterior temperature the state of charge may be predicted to insure the starting capacity of the vehicle. Also, vehicle communication telematic system 82 may also be used to obtain a prediction of the weather through a satellite 86 from a forecasting service such as the National Weather Forecasting Service 92 . Such information may be automatically received based on the position indicated by global positioning system 88 .
Battery controller 54 may also be coupled to ignition system 94 , which counts the battery cycles of the system.
By monitoring the state of charge of battery 64 and state of health prediction, the battery controller 54 may indicate to the vehicle operator long before problems arise that the battery may in the near future not be capable of starting the vehicle. As will be further described below, evasive measures may be performed such as disabling one or all of the loads 74 A- 74 C from the bus 70 .
Referring now to FIG. 3, the state of charge is monitored in step 100 . The state of charge may be monitored by monitoring the current and voltage of battery 64 using voltage monitor 76 and current monitor 78 . Outside temperature is monitored by temperature sensor 90 in step 102 . In step 104 , the state of health of the battery is also monitored. The state of health of the battery may be provided by monitoring the number of cycles through ignition system 94 , the discharge of battery 64 during each of the cycles, and the state of charge voltage measured in step 100 . In step 106 , the weather forecast is monitored using vehicle telematic system 82 , satellite 86 , and the forecasting service 92 . In step 108 , the measured state of charge from step 100 is compared to a predetermined state of charge. If the measured state of charge is less than the predetermined state of charge, step 110 is executed in which loads may be disabled based upon a state of charge or the state of health. In step 108 , if the state of charge is not less than the predetermined state of charge, step 112 is executed. In step 112 , if the state of health is not less than the predetermined state of health, step 100 is again executed. In step 112 , if the state of health is less than a predetermined state of health, step 110 is executed. Based on the measured state of charge and the measured state of health, loads may be disabled accordingly to provide an evasive action to maintain the power in the battery at a predetermined level so that the battery may provide enough power to the starter/alternator so that the starter/alternator may start the engine. In step 114 , the operator of the vehicle is warned of the low state of health or the low state of charge or both. The vehicle operator may be warned visually or audibly through indicator 80 or if the vehicle is sifting in the vehicle operator's remote, a page through satellite 86 or through a cell tower 84 may be provided to operator device 96 .
The predetermined state of charge in step 108 and the predetermined state of health 112 may be adjusted based upon the outside temperature monitored and a forecasted temperature as determined in step 106 . By providing an indicator to the operator in step 114 , evasive measures such as replacement of the battery or battery components or proper servicing may be performed to allow the vehicle to start.
While particular embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Accordingly, it is intended that the invention be limited only in terms of the appended claims. | A system ( 40 ) for an automotive vehicle has a temperature sensor ( 90 ) generating a temperature signal indicative of the temperature outside the vehicle and a battery. A battery controller ( 54 ) is coupled to the temperature sensor ( 90 ) and the battery ( 64 ). The controller monitors a state of charge of the battery ( 64 ), monitors a temperature outside of the vehicle and compares the state of charge to a predetermined state of charge. The predetermined state of charge is a function of the temperature. The controller ( 54 ) generates an indicator when the state of charge reaches the predetermined state of charge. | 8 |
FIELD OF THE INVENTION
The present invention relates to equipment, system and methods for improved downhole surveying and data acquisition at a drill site, such as for obtaining a core orientation sample and handling data relating to the sample.
BACKGROUND TO THE INVENTION
Drillers contracted by mining companies are required to drill numbers of exploratory subsurface drill holes at a chosen mine site to extract underground core samples in order to determine locations of mineralisation and the feasibility to proceed with mineral extraction.
Such operations extract a core during drilling (in ‘diamond drill-bit drilling’ the bit has a centre hole which allows the core sample to enter through during drilling). Core lengths are variable, but usually between 3 m and 6 m lengths and are extracted progressively for the entire hole.
Each extracted core sample is marked for its orientation position before extraction, with additional survey data of that cores position such as azimuth (angle of North-South deviation), dip angle, depth the core was extracted from and other additional data to verify data correctness. Financial costs associated with such operations are based on distance (meters) drilled, number of holes, sub-surface targets reached and number of targets concluded.
Drill-Rig Activity:
1) Equipment Needed to Achieve the Above Basic Requirements
Inventory of instrumentation and ancillary equipment required to carry out drilling activity such as surveying and core orientation. These pieces of equipment and sub-assemblies have to be possibly transported to remote locations by air cargo, helicopter or by road. In remote areas suitable for mining and drilling operations, such roads are often unsealed and within harsh environmental conditions.
2) Extracting Core Samples During Drilling
a) A core-orientation unit is attached to a ‘back-end assembly’, which is inserted into a drill hole during drilling and is brought to the surface when the core sample is extracted with the core orientation unit.
b) The core orientation unit needs to be removed (unscrewed) from the back-end assembly to begin the process of orienting the extracted core. The core is removed after orientation marking, and then the core orientation unit is re-installed to the back-end assembly before inserting into the drill hole for the next core sample extraction. This process is time consuming and costly considering the high cost of the drill rig on-site and that this process is repeated every 3 or 6 meters of drilling. Drilling depths are usually between 500 meters and 2 km, with deeper drilling expected in the future. To speed up the process, a pair of core orientation units are used on two identical assemblies and alternated when drilling for core samples, however the operator still needs to go through the motion of removing and re-installing the core orientation unit for every sample retrieved.
c) As drilling depths increases, the drill bit size is reduced to cope with the deeper hole drilling, as a consequence, a smaller size diameter core orientation unit is required to follow the reduced hole size. As a norm, drillers need to have three sizes of core orientation units, two of each size, making a total of six core orientation units. These units are usually made of heavy thick walled stainless steel to withstand high pressures during deep hole drilling. This adds substantial weight to the core orientation equipment inventory.
3) Surveying the Drill Hole at Different Depths
a) In order to identify the exact underground locations of each extracted core sample, a number of surveys of the drill hole need to be carried out in between the drilling and core extraction process. A survey instrument is used in the drill hole to measure azimuth, hole inclination (or dip), and other data. As a minimum, hole surveys need to be taken every 30 meters of drilling. The hole path/trajectory is then extrapolated mathematically and the extracted 6 m core samples positioning is then calculated from the plotted path.
b) The process of surveying a drill hole at a determined depth involves inserting a ‘Survey instrument probe’ into a pressure protected brass barrel, attaching the probe pressure barrel to three lengths of 1.2 m aluminium rod extensions (to avoid anomalous magnetic readings when the probe is in close proximity to the drill bit and steel drill pipe extensions), attaching the entire length to a back-end assembly, which is then inserted into the end of the drilled hole and through the hollowed centre of the circular drill bit. With the drill bit and steel piping pulled back past the survey probe and the three rod extensions, a survey reading can then be recorded at the last drilled position of the drill hole. This total assembly including the survey probe, its brass pressure barrel and three aluminium extension rods again adds substantial weight and considerable assembly/disassembly time to the survey process.
c) On retrieving the probe assembly, the probe needs to be removed from the brass pressure barrel in order to retrieve the recorded survey readings from the drill hole. This can be a lengthy process with added care required not to damage the instrument during handling or being dropped in water or mud as would normally be the condition at a drill-rig site.
4) Maintaining a Progressive Drilling Log
a) A mandatory requirement for all drilling activity is to record events, activities, instrument data and progress/achievement of underground targets. Traditionally (and still used in many drill rigs globally), the method of recording and logging of drilling activity is carried out painstakingly using manual pen and paper recording methods.
b) The pieces of paper are compiled and manually checked for errors or omissions, corrected after discussions with drill rig operators and on-site geologists, and then sent to the drilling companies' administrative office for manual transfer of data from the ‘progressive log of drilling’ sheets to computer terminals.
c) To accommodate for multiple site log data entry, there is usually a pool of typists performing the data entry task. Having to re-enter data in this manner can sometimes cause data errors which would then have to be re-checked and corrected as necessary. There is also the need to interpret the handwritten sheets to ensure data is recorded in the required format so it can be used by 3 rd party software programs which eventually provide billing to the mining companies that contract the drilling companies.
d) If sufficient detailed information can be recorded on the progressive log of drilling sheet process, the drilling company has the added advantage of extracting metrics from the recorded data that can provide a thorough analysis of drill-rig costs (labour and consumables), efficiencies, safety issues etc. This additional data is not always available due to insufficient data recording at the drill rigs because of inaccessibility of the data or time constraints when drilling towards underground targets within a limited time. Summary of current operational methods used for basic activities at drill-rig sites to orient core samples, measure survey data and record all activity at the drill rig site.
To accomplish the above, drill-rig operators use core orientation tools, survey probes and a number of manual pen and paper recording means to log drilling activity and events. Core orientation and Survey tools are available from a number of different international suppliers and attempts have been made to electronically record/log rig activity using ‘Tough-books’ and other commercially available laptops and hand-held computers. The problems experienced from present operating methods comes from having to manually record data from the variety down-hole instruments source from various 3 rd party suppliers, which may or may not have compatible formats, then transferring the data to the overall manual logging sheets or laptop as required for eventual recording and billing to customer.
This current method is prone to human error, possible data incompatibility and excessive time required to compile information which would require further re-compilation at head office to include other neighbouring drill-rig data and activity/events. Time delays and inherent inaccuracies as a result of manual human data recording can cause delays in invoicing and receiving payment, and at worst, not charging for all items due to missing or poor recording methods.
A further inconvenience to the driller is the need to keep an inventory of third party core orientation/survey instruments, different manufacturer spare parts and related consumables such as batteries, long and cumbersome brass pressure barrels to protect survey instruments, sealing/waterproofing ‘O’ rings and grease to install associated pressure barrel housings before using the survey probes. Apart from having to take stock of a large, and separately cased (if at all) collection of instruments with associated hardware and consumables, the operator has to gain familiarity with each instrument's method of operation and be able to manually record and integrate the various data formats and results into a common ‘paper form’ which can be later manually keyed in for geologist use or accounting purposes.
The present invention seeks to alleviate or overcome one or more of the aforementioned problems.
With this in mind, it is desirable of one or more forms of the present invention to provide a system or method that utilises a reduced number of components compared with standard systems and which enables common communication between various components.
It is further desirable of one or more embodiments of the present invention to make use of electronic hardware and software to reduce time and cost, with a reduction in overall equipment count and weight and the capability to simplify and streamline instrumentation and operator procedures.
SUMMARY OF THE INVENTION
One or more preferred forms of the present invention advantageously reduces complex operational methods prevalent at most drill rig sites, such as cumbersome handling and operation, incompatible equipment data outputs, and keeping track of multiple activity and events while operating the drill rig according to specified targets in a given time/cost budget.
At least one embodiment of the present invention provides a system incorporating reduced instrumentation component physical size(s) with the aid of component/module miniaturisation. This reduction in physical size of components allows for thicker wall pressure housings that enable component use in deep hole exploration/drilling.
Where preferred, use of composite materials may replace heavier brass and steel housings, making it possible to package pieces of equipment into one or more manageable (and preferably light weight) carrying cases. This adds the further advantage of lower shipment costs and portability, while being able to keep track of all components which fit into moulded receptacles in its carrying case. The instruments and hardware components in a system according to one or more embodiments of the present invention are built to be fully data and function compatible, so much so that a (preferably hand-held) control device is able to be used to initiate, interrogate and control all the survey/core-orientation instruments as well as log all drilling activity/events occurring at the rig.
As a system that offers essential instrumentation required for drill site measurement and logging, there is considerable reduction in size and the number of pieces of equipment in the system compared to presently known and used systems at mining drill-rig sites worldwide.
The following are components of a system according to at least one embodiment of the present invention that contribute to size reduction:
a) Magnetic Survey instrument probe in a short length form less than 500 mm, permanently encased in its own pressure barrel able to withstand pressures up to 6000 psi required for deep hole drilling applications. There is no need to dismantle the pressure barrel to operate or retrieve data from the probe. b) Compact but extendable lightweight ‘rod extensions’ to extend the Survey probe past the drill bit to avoid magnetic interference. Having a single short lightweight telescopically extendable piece is critical to keeping overall weight down. At present, the drilling industry typically uses three 1.2 meter solid/heavy aluminium rods joined together to achieve this. c) Lightweight composite material constructed dual core orientation instruments which can be started and after retrieval set up for core orientation, both without the need to be detached from the running gear/back-end assembly/core barrel. d) Adaptor attachments to each end of the core orientation instruments render the unit the capability to be used in all standard drill-hole sizes without having to stock different size instruments creating unnecessary duplication and additional space/weight. The attachments are compatible to LTK60, NQ, PQ, HQ and HQ2 drill strings and other drill string sizes commonly used in the industry. e) A controller or communication device, preferably a hand held controller, (with additional optional pocket size slave controller) that is able to operate all of the instruments in the system as well as optionally record and log all events and activity occurring at the drill-rig site. f) An easily attachable hand controller/communicator charging device (e.g. mains power or charging from a vehicle battery) which also optionally incorporates a satellite modem communicator for instant transfer of site data and progress logging for analysis, multi-rig monitoring or accounting purposes.
To further reduce human error and increase efficiency at the drill rig site, the included common hand-held controller is able to directly record rig operating conditions by optionally retrofitting rig instrumentation with compatible wireless data interface modules. This enables fast and accurate rig status data acquisition, further automating progressive log of drilling activity.
The system and method of the present invention provides on-site multiple function data integration of simultaneous activity occurring at the rig site without the need for manual recording or calculations. Human error factors are reduced leading to increased work efficiency and safety.
An aspect of the present invention provides a survey system for obtaining data from a drilling operation, the system including at least one core orientation instrument for use in determining orientation of a core sample, at least one downhole survey probe for use in determining characteristics relating to a borehole created during a drilling operation, and a common single controller configured to control or communicate with both the at least one survey probe and the at least one core orientation instrument.
The controller may be arranged to capture survey data and core orientation data, and to transmit said survey and core orientation data in electronic form to a data capture means for later use.
The controller may include means to capture or receive progress log of drilling data.
The controller may be arranged to transmit said progress log of drilling data to the data capture means.
The system may further include at least one telescopic rod extension for direct or indirect connection to the survey probe or the core orientation instrument. The telescopic rod extension may include at least one side wall incorporating or predominantly formed of composite material.
By including one or more adapters for attachment to an end or both ends of the core orientation instrument or survey probe, said adapter(s) may vary the effective diameter of the core orientation instrument or survey probe for attachment to drill string extension components having a respective connecting thread diameter greater than the diameter of a connecting thread of the core orientation instrument or survey probe.
A respective said adapter may be releasably attachable to the core orientation instrument or to the survey probe. Multiple sizes, such as small medium and large (relative to one another) diameter adapters may be provided. A large diameter one of the adapters may be arranged to connect to a smaller diameter said adapter, or said large diameter adapter is arranged to replace said smaller or medium (intermediate size) diameter adapter.
A survey system including multiple components may be arranged to be housed in a portable container for transport and deployment at a drilling site, the multiple components including a survey probe, a core orientation instrument and a single controller configured to control or communicate with the survey probe and core orientation instrument.
The system may further include a telescopic rod extension, thereby alleviating the need for multiple extension rods of fixed length.
Multiple sized adapter collars may be used in adapting the core orientation instrument to threadingly engage with a selected extension barrel.
A further aspect of the present invention provides a method of collecting survey data from a drilling operation, the method including: providing a survey system, the system including at least one survey probe, at least one core orientation instrument and a common single controller, collecting data in the controller from the survey probe and the core orientation instrument, and transmitting said collected data to a data capture means.
The method may include the controller communicating with at least one survey probe, core orientation instrument or drilling operation remote from the controller.
Another aspect of the present invention provides at least one adaptor for attachment to an end of a core orientation instrument or survey probe for use in a survey system, the adaptor including attachment means to releasably attach the adaptor, and thereby the core orientation instrument or survey probe, to at least one drill string component.
The core orientation instrument or survey probe can then be used in a variety of (standard) drill-hole sizes at or greater than the size of the instrument or probe without having to stock different size instruments creating unnecessary duplication and additional space/weight. The adaptor(s) may be compatible to LTK60, NQ, PQ, HQ and HQ2 drill strings and other drill string sizes commonly used in the industry.
Preferably at least one said adaptor is provided for each of the two ends of a core orientation instrument or survey probe. Thus, each end of the instrument or probe can be adapted to connect to a selected same size or larger size drill string component ahead of and behind the instrument or probe.
The at least one adaptor may be releasably attached to the instrument or probe, such as by one or more screw threads, retaining screws, bolts, clips or pins. The adaptor may include a screw thread at one end thereof for releasable engagement with an corresponding screw threaded end of the instrument or probe, and another screw thread at the opposite end of the adaptor for engagement with a corresponding screw thread of another adaptor or a drill string component. Thus single or multiple adaptors may be used to convert the smaller diameter instrument or probe to larger diameter drill string components.
The adaptor may include at least one aperture through a side wall thereof, which allows light from an optical instrument to pass to or from the core orientation instrument or survey probe relative, or to allow lubrication fluid to flow through the adaptor, to or from an exterior.
A weld connection may be provided between the adaptor and the core orientation instrument, the survey probe or the at least one drill string component to prevent subsequent release of the adaptor.
A second controller may be provided. This may be in the form of a handheld device, optionally with reduced functionality compared with the common controller, such as a master controller and slave controller arrangement. The second controller may be configured to communicate with the common controller.
A controller power pack may be provided to supply electrical power to the second controller, and optionally a communication dock enabling data communication between a portable memory device and the second controller when the second controller is docked therewith may be provided. The dock may include a USB port for removable connection of a USB device, such as a memory stick or ‘thumb drive’.
The common controller may be arranged and configured to capture survey data or core orientation data, and to transmit said survey or core orientation data in electronic form to a data capture means for later use.
The second controller may also be arranged and configured to capture survey data or core orientation data, and to transmit said survey or core orientation data in electronic form to a data capture means for later use.
The second controller may be arranged and configured to transmit data to the common controller for assimilation or use with other data in the common controller or for transmission to an external data capture device.
The common controller may include means to capture or receive progress log of drilling data. The common controller may also be arranged and configured to transmit said progress log of drilling data to the data capture means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows currently used equipment in surveying at a drill site and capturing drilling data.
FIG. 2 shows an embodiment of the present invention with reduced number of components compared with currently used systems and including improved data capture and component control through an electronic controller.
FIG. 3 shows a core orientation instrument with adaptors according to an embodiment of the present invention.
FIGS. 4 a and 4 b show in cross section an adaptor for a core orientation instrument according to an embodiment of the present invention.
FIGS. 5 a to 5 c show alternative versions of an adaptor for a core orientation instrument according to an embodiment of the present invention.
FIG. 6 shows a set of downhole survey system equipment in a storage means for protection and transport.
DESCRIPTION OF PREFERRED EMBODIMENT
A known system 10 will first be described with reference to FIG. 1 . FIG. 1 shows a comparison of currently required equipment to carry out surveying, core orientation using three sizes for varying drill hole diameters in deep hole drilling, and logging all events and activity at a drill-rig site.
Extracting Core Samples During Drilling
As with the description of known systems and components in the background section above, the common system 10 and method for core extraction and orientation requires a process of dismantling at least two assembly sections to complete the orientation. As every 3 m or 6 m requires core orientation, a significant amount of time is spent during this process. For deep hole drilling where at least three hole sizes are encountered, the equipment count (and weight) for core orientation equipment almost trebles (as seen in FIG. 1 ). This occurs because a relatively wide borehole can first be drilled. As friction increases with depth, a narrower hole is needed, and then again a third much narrower drill. Thus, three different diameters of core orientation instruments 18 , 20 , 22 are required to match the three different drill widths. This significantly increases the number of components required in a known system. Matching extension barrels (drill string extensions) are also required to connect the core orientation instrument 18 , 20 , 22 to the drill string. Because there are three hole sizes, there are three matching extension barrels 24 . A core orientation instrument controller 28 is used to control and communicate with the core orientation instrument. This is in addition to a separate survey probe controller, typically because these instruments may come from different manufacturers or are supplied as stand alone sub systems.
Surveying the Drill Hole at Different Depths
The survey instrument/probes 12 used in today's mining industry are of an average length of 1 m or more. They all require operation in a brass pressure barrel 14 which needs to be disassembled from one end (at least) to start the probe's operation and again to stop operation and extract data after removal from a drill-hole. It is inherent for all magnetic survey instruments that an average of 5 m separation of its sensors from the drill bit and steel drill pipes is required before making a valid reading. This is achieved using multiple solid aluminium rod extensions 16 . A survey instrument controller 26 is used to control the survey instrument and obtain data from the instrument.
Keeping a Progressive Log of Drilling
As described above and shown in FIG. 1 , the industry norm is to use handwritten forms and faxes 30 through to typing pools for data entry 32 and eventual analysis/reporting of data and accounting 34 . This long standing method is plagued with human error and lost opportunity through inefficient double and triple handling of data collection and recording drill-rig activity. Client billing cycles are delayed and only sparse analysis (if at all) is available from the collected data.
An embodiment of the present invention is shown in FIG. 2 . Such a system requires fewer components than needed in a known system. Replaceable adapters on the core orientation unit replace the various sizes of core orientation units in known systems. This is a significant saving in equipment costs and operational costs, as well as avoiding the need to transport the additional electronic equipment to and from sites.
Extracting Core Samples During Drilling
For extraction of core samples, the system 38 shown in FIG. 2 uses a single size (smallest diameter size) core orientation unit 18 with multiple size adaptors 46 , 48 to match with different stages of deep-hole drilling. This beneficially avoids the need for multiple size core orientation instruments used in the known systems.
Drill string extensions 50 , 52 , 54 are utilised. Only one section needs to be dismantled to remove the core sample as this core orientation unit has a unique facility to communicate internal data without the need to remove the unit from its back-end attachment.
Surveying the Drill Hole at Different Depths
A system of the present invention can utilise state-of-the-art SMT (Surface Mount Technology) or wire bonding miniaturisation to achieve a survey instrument probe 40 no longer than half a meter (500 mm), be fully encased in its own brass pressure housing, will not need dismantling for the start/stop/extract data process, and achieves magnetic sensor separation using an extendable/telescopic, preferably composite, material extension rod 42 . The probe 40 is designed to operate in harsh environments, and with thicker wall pressure housing (due to internal electronic component miniaturisation), is easily adaptable for deep-hole drilling.
Keeping a Progressive Log of Drilling
As seen in FIG. 2 , a system of the present invention integrates all functions of an electronic controller 56 with core orientation and survey instrumentation 40 , 44 , thereby only requiring a single controller rather than the multiple controllers of the known art. The controller can provide seamless and instant electronic data capture and communication for the drilling companies, newly designed hardware and software functions will empower the driller to operate from a central singular (hand-held) controller, with full access and monitoring/validation of all instrument data, consumables, drilling target progressive achievement and full analysis of work progress at the mine site.
The single common controller for communicating with and controlling the core orientation instrument/unit and also the probe(s) avoids the need for multiple controllers. Furthermore, data capture by one controller allows different data sets to be compared or used to derive further data. For example magnetic field data from a probe can be combined with core orientation data to help determine subsurface geological features or potential sites for deposits.
FIG. 3 shows a core orientation instrument 60 with a central body 62 for housing electronics, a first threaded end 76 and a second threaded end 78 . The first threaded end is arranged to receive an adaptor 64 . This adaptor has an external threaded portion 70 for connection to drill string component, such as a greater unit (not shown). This first adaptor 64 includes an internal thread 80 arranged to threadingly engage with the external first threaded end 76 . After screwing the adaptor 64 onto the first end of the core orientation instrument, a circlip 68 is applied to retain the adaptor in place. The circlip engages into grooves 72 through the wall of the adaptor. To prevent the adaptor from unscrewing form the end of the core orientation instrument, the circlip will engage against a shoulder of the end of the core orientation instrument. The circlip must be removed before the adaptor can be unscrewed. At the other end of the core orientation instrument, another external thread 78 is arranged to engage with an adaptor 66 . This adaptor has spaced apertures 74 to allow light to transmit data from the core orientation instrument to a light receiver or controller. This adaptor can connect the core orientation instrument to a core barrel. It will be appreciated that the adaptors can be used with other survey tools, such as survey probes.
FIGS. 4 a and 4 b show an adaptor in cross section. FIG. 4 a shows the adaptor before it is threaded onto the end of the core orientation instrument, and FIG. 4 b shows the adaptor attached and the retaining circlip in place.
FIGS. 5 a to 5 c show alternative arrangements for releasably attaching the adaptor to the core orientation instrument. FIG. 5 a shows a circlip type retainer, FIG. 5 b shows a multiple retaining screw (grub screw) alternative. The retaining screws screw into threaded holes through the wall of the adaptor and bite into the wall of the core orientation instrument or engage into holes in the casing of the body. In FIG. 5 c , a screw threaded locking collar or sleeve 84 threads onto an external thread 82 of the adaptor. Tightening the collar or sleeve clamps the adaptor to the core orientation instrument.
The external threads 70 , 78 of the adaptors can be sized to suit the matching required size of the drill string components. Thus, instead of requiring various sizes of core orientation instrument or other survey instrument, only one smaller size of instrument is required and the end connections can be adapted by use of the adaptors to suit a required size of corresponding drill string components. This reduces the number of components required for a survey system, reduces overall capital cost, avoids the need for multiple electronics instruments, and makes the entire system portable in a transportable case.
In use, the second controller may be used to capture data for one surveying task, such as core orientation data, whilst the common controller (considered a master or primary controller) is used for data on a second task, such as handling a log of drilling or survey probe data. All data may be combined by data transmission into one of the controllers, preferably the common controller. Data transmission may be infra red or wireless communication directly from one controller to the next, or from on controller via a docking station to a memory device and thence into the second controller. Alternatively, data from both controllers may be transmitted to a remote device, such as a computer, for further processing.
The docking station may also act as a power charger for an on-board battery in one or both controllers. An AC and/or car battery supply adapter/transformer may be provided as part of the downhole survey system equipment to aid with power and charging of the controllers. Data transmission equipment may also be provided, such as a Wifi or satellite communication enabled device to transmit data to a remote location or device.
FIG. 6 shows components of a downhole survey system 100 according to an embodiment of the present invention. The components are housed in a container for safe transport to and from a drill site and for secure storage. This prevents damage to the components and ensures all components in the system are accounted for by providing a particular storage position for each component. The components in the embodiment are shown housed in a protective foam inlay 102 that sits inside the container (not shown). The components include a downhole probe 104 , and extension rod 106 (which may be of a preselected length or may be telescopic) to connect the probe to a drill string or other components. One or more downhole instruments, such as core orientation units 108 , 110 , can be included. The system further includes the option to use adaptors 112 , 114 , 116 , 118 etc, to connect one or more of the instruments and/or probes to a drill string. The adaptors are provided according to one or more embodiments of the adaptor of the present invention. One or more of the adaptors includes at least one aperture for entry/exit of light for communicating data to or from an instrument or probe. The system further includes a hand held electronic common controller 120 to receive, transmit and store data relating to a drilling operation obtained by the probe or a core orientation unit. The controller is termed a common controller because it operates with both the probe and at least one of the instruments. Such a controller can communicate with the probe and one or more of the other instruments in the system to receive or send data or instructions to operate the probe or instrument(s) or report on drilling activities, such as a log of drilling. The controller includes a display screen. A second controller 121 is also provide stored underneath the common controller. This second controller can be a slave controller providing reduced functionality compared to the common controller. The second controller can be used to communicate with one of the probe or instrument while the common controller is used to communicate with another of the probe or instrument, or to report on drilling activities, such as a log of drilling. A charging device 122 is also provided. This acts as a power source to charge an on-board respective battery for the common controller and/or second controller. The charging device may provide communication through wifi and/or satellite to a remote device or location. A shock absorber device 124 is also provided to limit shocks through the probe and instrument(s) when in use downhole. Tools, such as spanners 126 are also provided, as well as a core orientation determining device 128 . | An adaptor ( 64,66 ) has attachment means to releasably attach a core orientation instrument ( 60 ) or survey probe to a drill string component and/or drill string, preferably by one or more screw threads ( 70, 72, 76, 78 ), retaining screws, bolts, clips or pins or welding/soldering. Anti release means, such as a circlip, can be used to prevent release of the adaptor. A survey system for obtaining data from a drilling operation includes a core orientation instrument, a downhole survey probe and a common single remote controller/data logger configured to control or communicate with both the survey probe and the core orientation instrument. Further, a survey system includes multiple components arranged in a portable container for transport and deployment at a drilling site include a survey probe, a core orientation instrument and a single controller configured to control or communicate with the survey probe and core orientation instrument. | 4 |
FIELD OF THE INVENTION
This invention relates to electrical switches, and more particularly to switches controlling the operation of electronic flashlights.
DESCRIPTION OF THE RELATED ART
Contemporary small, portable lights or flashlights most commonly use one spring and one fixed contact for connections to the cathode and anode of a dry cell battery, respectively. The spring in these units commonly presses into and connects with the cathode of the dry cell battery, and said spring's spring force is used to press the dry cell battery's anode into a second, fixed contact, inferior to the bulb assembly. Metallic straps or wires are used to connect these contacts sequentially to the flashlight's bulb and power switch, respectively providing means for conveying electrical power to the flashlight's bulb, and for interrupting that power to turn the light on and off. In the case of flashlights with metallic bodies the body itself may serve as part of the circuit, replacing one of the conductors. Examples of this scheme are ubiquitous in flashlights made by Ray-O-Vac, Duracell, Garrity, Mag Instruments, among others.
Switches commonly used in the above scheme include sliding switches, such as a thumb-activated slide mechanism on the outside of the flashlight body, and pushbutton switches, either mounted in the body of the flashlight, or at the tailcap. All of these switches require penetration of the flashlight body, leaving gaps and openings through which water can enter and ruin the flashlight. Slide switches in particular are vulnerable to leakage. Further, while rubber domes with round rubber gasket skirts have been developed to cover pushbutton switches, providing some measure of water resistance, the result falls short of full water-tightness.
Other flashlights of contemporary design, such as the Energizer Waterproof flashlight model WP250WB-E, comprising a plastic body and a twist-on head, incorporate a “twist-on” switch. Said switch is operated by rotating the flashlight's head, clockwise turning the flashlight on, and counterclockwise to turn the flashlight off. Such switches have the great advantage of being entirely inside the flashlight's body, with water-tightness ensured by o-ring seals that seal the flashlight's head to its body. Water-tightness can be achieved at depths exceeding 100 meters of water. This switch comprises a rigidly mounted contact in the head assembly which, when the head is operated, is pressed into contact with the anode of a dry cell installed beneath it. Said switch, while effective in a conventional incandescent flashlight, does not provide means for controlling a multiplicity of modes for a more flexible, more capable electronic flashlight.
SUMMARY OF THE INVENTION
The advent of light emitting diodes (LEDs) has resulted in a new array of lighting products with capabilities unavailable in older, incandescent-based products. The instant invention discloses an electrical switch suitable for controlling the operation of a more advanced flashlight, especially one with multiple modes.
The preferred embodiment teaches how a spring—such as a helical spring fashioned of steel, stainless steel, copper alloy, brass, or other suitable metal or alloy, with or without chromium or other protective plating—can be combined with a suitable array of contacts to produce a multi-position shorting switch that is inexpensive, durable, and reliable. Said switch can be readily fabricated on one side of a printed circuit board, allowing it to operate circuitry assembled on the opposite side of same. Furthermore, said switch can be contained within the protective environment of the flashlight housing, facilitating construction of waterproof flashlights.
Additionally, the instant invention provides for contacting an electrode of a dry cell, thus combining an additional function without additional cost, reducing parts count, and reducing the number of interconnection points in the flashlight's electrical circuit. Reliability is accordingly increased.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a cut-away view of the invention.
FIG. 2 is a top-view of the contact assembly.
FIGS. 3 a–c are cut-away views of the invention in various stages of operation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 depicts one preferred embodiment of the invention. A helical spring 101 made of a suitable electrically conductive material such as (but not limited to) steel, stainless steel, copper alloy, brass, or other suitable metal or alloy, with or without chromium or other protective plating, possessing coils 102 – 108 , is positioned over concentric annular contacts 201 – 203 . Said contacts 201 – 203 may be conductors laminated to a printed circuit board. 109 . Connections 111 connect contacts 201 – 203 to circuitry 110 .
FIG. 2 is a top-view of contacts 201 – 203 , showing said contacts as well as insulating gaps 204 – 205 . Gaps 204 – 205 serve to electrically isolate contacts 201 – 203 from each other until such time as the invention is activated. Contacts 201 – 203 may be supported by an insulating substrate, such as a fiberglass printed circuit board. Depiction of connections from contacts 201 – 203 to external circuitry has been omitted for clarity, but should be obvious to those skilled in the art.
OPERATION OF THE INVENTION
FIG. 3 a depicts a first state in which dry cell 301 has been positioned so that its anode 302 has just begun to touch coil 105 of spring 101 . Spring 101 's coils 102 – 108 are therefore only slightly compressed, none sufficiently to be advanced into contacts 202 or 203 . In this first state, spring 101 is in electrical and mechanical contact with contact 201 . This creates a first circuit, connecting battery anode 302 with contact 201 via spring 101 . In this first state contacts 202 and 203 are open circuits.
FIG. 3 b depicts a second state in which dry cell 301 is applying an additional compressing force to spring 101 , as would happen, for example, if the entire switch assembly comprising 101 – 108 and 201 – 205 were squeezed partially together with dry cell 301 . Said compression of spring 101 forces coils 103 and 107 into contact with contact 202 , creating a second circuit. Said second circuit electrically connects battery anode 302 with contacts 201 – 202 via spring 101 .
FIG. 3 c depicts a third condition in which dry cell 301 has advanced sufficient distance to fully compress spring 101 . Coils 103 and 107 are pressed into mechanical and electrical contact with contact 202 , and coils 104 – 106 are forced into contact with contact 203 , creating a third state. In this third state spring 101 electrically connects battery anode 302 to all of the contacts 201 – 203 .
In brief, this preferred embodiment of the invention yields a single-pole, three-position shorting switch that can simultaneously provide connection to a battery. This switch can be used wherever a shorting single-pole multiple-position switch is desired, such as for controlling the brightness level or other operating mode of an electronic flashlight.
Although one preferred embodiment of the invention has been described, numerous embodiments in the spirit of the present invention will be apparent to those skilled in the art. For example, more or fewer than the three contacts 201 – 203 depicted in FIG. 2 may be used, adapting the invention to circumstances needing more or fewer switch positions. If an initial open circuit condition is desired, annular contact 201 may be omitted, or the space between spring 101 and dry cell 301 may be increased until the two do not initially touch. FIG. 3 depicts the invention being operated by the anode 302 of a dry cell 301 , however the invention can be operated equally well by either electrode of a dry cell, or by an external mechanical plunger if desired. A helical spring 101 has been shown and is preferred for cost, simplicity, and performance, but a cantilevered lever arm or a metallic “snap” dome may be substituted to perform the same function. The contacts 201 – 203 need not be of annular configuration, but may take other shapes, such as concentric rings with finger-like projections that interleave in gaps 204 – 205 with similar projections from the opposing contact, pie-shaped wedges, among other shapes. Lastly, contacts 201 – 203 need not be flat, but can contained raised structures such as solder bumps, or other conductive bumps or contact areas designed to raise the contact force, lowering contact resistance. Bare metal “jumper” wires, positioned at various radii and oriented 90 degrees to spring coils 201 – 203 are another such alternative contact structure. All of these alternatives flow from and are anticipated in the practice of the instant invention. | An electrical switch comprising a helical spring, progressively compressed onto concentric annular contacts, provides a mechanism for operating a portable light or other devices, and for engaging multiple modes of operation of said device(s), for example a portable electronic flashlight. | 5 |
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
NOT APPLICABLE
CROSS-REFERENCES TO RELATED APPLICATIONS
NOT APPLICABLE
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
NOT APPLICABLE
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related generally to the field of orthodontics. More particularly, the present invention is related to methods and systems for dispensing a series of orthodontic appliances in a sequence to a patient.
Repositioning teeth for aesthetic or other reasons is accomplished conventionally by wearing what are commonly referred to as “braces.” Braces comprise a variety of appliances such as brackets, archwires, ligatures, and O-rings. Attaching the appliances to a patient's teeth is a tedious and time consuming enterprise requiring many meetings with the treating orthodontist. Consequently, conventional orthodontic treatment limits an orthodontist's patient capacity and makes orthodontic treatment quite expensive. Moreover, from the patient's perspective, the use of braces is unsightly, uncomfortable, presents a risk of infection, and makes brushing, flossing, and other dental hygiene procedures difficult.
As a result, alternative methods and systems for repositioning teeth have been developed. For example, repositioning may be accomplished with a system comprising a series of appliances configured to receive the teeth in a cavity and incrementally reposition individual teeth in a series of at least three successive steps. Most often, the methods and systems reposition teeth in from ten to twenty-five successive steps, although complex cases involving many of the patient's teeth may take forty or more steps. The individual appliances are typically comprised of a polymeric shell having the teeth-receiving cavity formed therein, typically by molding. The successive use of a number of such appliances permits each appliance to be configured to move individual teeth in small increments.
Typically the systems are planned and all individual appliances are fabricated at the outset of treatment. Thus, the appliances may be provided to the patient as a single package or system. The order in which the appliances are to be used can be marked by sequential numbering directly on the appliances or on tags, pouches or other items which are affixed to or which enclose each appliance so that the patient can place the appliances over his or her teeth in an order and at a frequency prescribed by the orthodontist or other treating professional. Successive appliances will be replaced when the teeth either approach (within a preselected tolerance) or have reached the target end arrangement for that stage of treatment, typically being replaced at an interval in the range from 2 days to 20 days, usually at an interval in the range from 5 days to 10 days.
In general, it is preferable to simplify procedures for the patient to increase patient compliance and reduce patient errors in carrying out the treatment protocol. Therefore, it is desirable to utilize a packaging or ordering system which will provide appliances to a patient in a manner which is clearly discernable to the patient the order of the appliances. In addition, such packaging or ordering system should be amenable to mid-treatment changes to the treatment protocol, possibly adding or eliminating appliances after the initial set of appliances has been produced and packaged. At least some of these objectives will be met by the methods and systems of the present invention described hereinafter.
2. Description of the Background Art
Tooth positioners for finishing orthodontic treatment are described by Kesling in the Am. J. Orthod. Oral. Surg. 31:297-304 (1945) and 32:285-293 (1946). The use of silicone positioners for the comprehensive orthodontic realignment of a patient's teeth is described in Warunek et al. (1989) J. Clin. Orthod. 23:694-700. Clear plastic retainers for finishing and maintaining tooth positions are commercially available from R AINTREE E SSIX , I NC ., New Orleans, La. 70125, and T RU -T AIN P LASTICS , Rochester, Minn. 55902. The manufacture of orthodontic positioners is described in U.S. Pat. Nos. 5,186,623; 5,059,118; 5,055,039; 5,035,613; 4,856,991; 4,798,534; and 4,755,139.
Other publications describing the fabrication and use of dental positioners include Kleemann and Janssen (1996) J. Clin. Orthodon. 30:673-680; Cureton (1996) J. Clin. Orthodon. 30:390-395; Chiappone (1980) J. Clin. Orthodon. 14:121-133; Shilliday (1971) Am. J. Orthodontics 59:596-599; Wells (1970) Am. J. Orthodontics 58:351-366; and Cottingham (1969) Am. J. Orthodontics 55:23-31.
BRIEF SUMMARY OF THE INVENTION
The present invention provides systems and methods for providing dental appliances, particularly orthodontic appliances, to a patient wherein the patient is easily able to determine the order or sequence in which the appliances should be worn. Typically the appliances are to be worn in a particular sequence to provide desired treatment, such as a progressive movement of teeth through a variety of arrangements to a final desired arrangement.
In a first aspect of the present invention, a system of dental appliances is provided comprising a plurality of dental appliances wherein at least some of the plurality include a non-numeric indicia designating an order in which each of the at least some of the plurality are to be worn by a patient to provide dental treatment. Typically, each of the plurality of dental appliances comprise a polymeric shell having cavities shaped to receive and resiliently reposition teeth from one arrangement to a successive arrangement. Exemplary embodiments of such dental appliances are described in U.S. Pat. No. 5,975,893, incorporated herein by reference for all purposes. In some embodiments, each of the polymeric shells has at least one terminal tooth cavity and the indicia comprises a terminal tooth cavity of differing length in each of the polymeric shells. In other embodiments, each of the polymeric shell has a height and the indicia comprises a different height in each of the polymeric shells.
In still other embodiments, the indicia comprises one or more cutouts so that each polymeric shell has a different cutout pattern. Sometimes the cutout comprises a notch in an edge of the appliance.
In yet other embodiments, the indicia comprises a color wherein each appliance has different color. The color of the appliances may have the same hue and vary by intensity, for example. The color may comprise a dissolvable dye. Or, the system may further comprise a wrapper removably attachable to each of the appliances, wherein each wrapper has the color.
In another aspect of the present invention, a system of packaged dental appliances is provided comprising a plurality of packages each containing a dental appliance, wherein the plurality of packages are joined in a continuous chain designating an order in which each of the dental appliances are to be worn by a patient to provide dental treatment. In some instances, the packages are each joined by a perforation wherein the packages can be separated by breaking the perforation. In other instances, the packages are joined by, for example, a heat seal. Further, the system may include a marking on a package at an end of the chain indicating the dental appliance to be worn first. Again, each of the plurality of dental appliances may comprise a polymeric shell having cavities shaped to receive and resiliently reposition teeth from one arrangement to a successive arrangement.
In a further aspect of the present invention, a system of dental appliances is provided comprising a plurality of dental appliances to be worn by a patient to provide dental treatment, and a framework, wherein each of the plurality of dental appliances are removably attached to a portion of the framework. In some embodiments, each of the plurality of dental appliances comprise a polymeric shell having cavities shaped to receive and resiliently reposition teeth from one arrangement to a successive arrangement. Further, the system may comprise at least one marking on the framework indicating the order in which the appliances are to be worn by a patient.
In still another aspect of the present invention, method of dispensing dental appliances to a patient is provided. The method including the step of providing a plurality of packages wherein each of the packages includes a polymeric shell having cavities shaped to receive and resiliently reposition teeth from one arrangement to a successive arrangement, the plurality of package including a first package containing a first shell to be worn by the patient to reposition the teeth from the one arrangement to the successive arrangement and a second package containing a second shell to be worn by the patient to reposition the teeth from the successive arrangement to another successive arrangement. The method further including the steps of delivering the first package to the patient at a designated time through a remote delivery system, and delivering the second package to the patient at a later designated time through the remote delivery system. In most embodiments, the remote delivery system comprises a mail delivery system.
In another aspect of the present invention, a method is provided of dispensing dental appliances to a patient including providing a dispenser including a plurality of dental appliances, wherein each of the appliances comprises a polymeric shell having cavities shaped to receive and resiliently reposition teeth from one arrangement to a successive arrangement, the plurality of appliances including a first shell to be worn by the patient to reposition the teeth from the one arrangement to the successive arrangement and a second shell to be worn by the patient to reposition the teeth from the successive arrangement to another successive arrangement, and removing the first shell from the dispenser wherein removal of the first shell dispenses the second shell.
In a further aspect of the present invention, a method of dispensing dental appliances to a patient is provided including providing a dispenser including a plurality of dental appliances, wherein each of the appliances comprises a polymeric shell having cavities shaped to receive and resiliently reposition teeth from one arrangement to a successive arrangement, the plurality of appliances including a first shell to be worn by the patient to reposition the teeth from the one arrangement to the successive arrangement and a second shell to be worn by the patient to reposition the teeth from the successive arrangement to another successive arrangement. The method further includes removing the first shell from the dispenser, and actuating an actuator that subsequently dispenses the second shell. In most embodiments, the actuator comprises a lever, knob, or button.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a series of appliances dispensed in a chain.
FIG. 2 illustrates a series of appliances disposed on a framework.
FIG. 3 illustrates a series of appliances provided to a patient in a dispenser.
FIGS. 4A-4B illustrate a change in length of a terminal tooth cavity between appliances in a series.
FIGS. 5A-5B illustrate a change in height between appliances in a series.
FIGS. 6A-6B illustrate the addition of cutouts in each appliance to indicate an order.
FIGS. 7A-7C illustrate a change in color to indicate an order.
FIG. 8 illustrate an embodiment of a method of delivering appliances in a desired order.
FIG. 9 illustrates an appliance which includes a readable element embedded in the appliance.
FIG. 10 illustrates a series of packages 12 , each having a label which includes at least one non-numeric indicia.
FIG. 11 illustrates a package of dental appliances of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
It may be appreciated that the orthodontic appliances may be dispensed to the patient in its entirety, in groups or individually. Providing the patient with the entire series at the outset of treatment may be desirable if the treatment plan is relatively short, the patient is particularly compliant, or it is particularly convenient, to name a few. In this case, the series should be ordered so that the patient can easily selected the next appliance in the sequence when needed. Such ordering may be designated through packaging or the appliance itself. In some situations, the patient may receive additional appliances during the treatment protocol for inclusion in the sequence and/or the patient may receive instructions to eliminate some of the original appliances from the treatment protocol. Therefore, such ordering should allow easy incorporation of additional appliances or deletion of appliances.
Alternatively, the patient may be provided with a subset of the entire series, such as the first ten appliances. In this case, the subset should be ordered so that the patient can easily selected the next appliance in the sequence when needed. Again, such ordering may be designated through packaging or the appliance itself. The patient may receive additional appliances during the use of the subset for inclusion in the sequence and/or the patient may receive instructions to eliminate some of the original appliances from the subset. Alternatively, the next subset of appliances may differ from that which was initial determined at the outset of the treatment protocol. Therefore, such ordering should allow easy incorporation of additional appliances or deletion of appliances within or between subsets.
Further, the patient may be provided with individual appliances in the order in which they should be used. In this case, the appliances should be ordered so that the patient can easily differentiate the appliance they are receiving from the appliances already received. Again, such ordering may be designated through packaging or the appliance itself. In addition, such ordering should allow the appliances to be stored and distributed to the patient in the correct sequence with minimal attention from the orthodontic practitioner.
A variety of embodiments of ordering systems and methods will be described. In a first embodiment, a series of appliances are dispensed to the patient in a continuous chain, wherein the appliances are to be used in the sequence of the chain. An example of such a chain is schematically illustrated in FIG. 1 . Here, each appliance 10 is disposed within a package 12 , wherein the packages 12 are joined together in a continuous chain. In this embodiment, each package 12 is separable at a perforation 14 from the remaining packages 12 in the chain. It may be appreciated that the packages may be joined and/or are separable in any suitable manner including with the use of adhesives, heat sealing, ultrasonic welding, linkages or simply indications where to cut, break or separate, to name a few. To indicate the end of the chain in which it begin use, a marking may be located on the package 12 or on the appliance 10 . For example, a colored marking 16 may be located on an end package 12 a , as shown. This would indicate that a first appliance 10 a is enclosed. Once the first appliance 10 a has been removed from the package 12 a and worn for a given amount of time, the patient may then open a next package 12 b in the chain and remove a second appliance 10 b for wearing. This may be repeated throughout the chain.
In another embodiment, illustrated in FIG. 2 , a series of appliances 10 are disposed on a framework 20 , such as a sprue. Sprues typically secure objects, such as molded objects, before their first use. The appliances 10 are secured to the framework 20 in any suitable manner. The appliances 10 are then removed from the framework 20 according to a the treatment protocol. For example, the first appliance 10 a to be used may be disposed at one end of the framework 20 , the second appliance 10 b disposed next to the first appliance 10 a , the sequence continuing along the framework 20 . Alternatively or in addition, markings may be disposed on the framework 20 or the appliances 10 themselves indicating an ordering of use.
In another embodiment, illustrated in FIG. 3 , a series of appliances 10 are provided to a patient in a dispenser 30 . The dispenser 30 dispenses the appliances 10 in the order to be used. Each appliance 10 may be individually dispensed, as shown, or each appliance 10 may be contained in a package wherein the packages are individually dispensed. The dispenser 30 may include an actuator 32 , such as a lever, button, switch, etc, so that actuation of the actuator 32 dispenses the appliance 10 or package containing the appliance 10 . Alternatively, removal of an appliance 10 from the dispenser 30 may actuate dispensing of the next appliance 10 . In this way, the patient is systematically dispensed appliances in a predetermined order of use.
In some situations it may be desired to specifically mark the appliances themselves. Such markings ensure that ordering of the appliances is distinguishable after removal of the appliances from any packaging and during use. For example, a portion of each appliance may be changed to indicate a sequence or order. FIGS. 4A-4B illustrate a change in length of the appliance 10 by changing the length of a terminal tooth cavity 40 . A terminal tooth cavity 40 is one of the last teeth in the appliance. FIG. 4A illustrates a first appliance 10 a wherein a marked terminal tooth cavity 40 a has a given length. FIG. 4B illustrates a second appliance 10 b wherein a marked terminal tooth cavity 40 b has a length which differs from the first appliance 10 a . Here, the marked terminal tooth cavity 40 b has a shorter length. The lengths can continue to differ throughout the sequence of appliances. Alternatively or in addition, the lengths of other terminal teeth may differ.
FIGS. 5A-5B illustrate a change in the height of each appliance 10 to indicate a sequence or order. The height of the appliance 10 is the distance from the occlusal surfaces 46 to the edges 48 of the appliance 10 . FIG. 5A illustrates a first appliance 10 a having a given height. FIG. 5B illustrates a second appliance 10 b having a height which differs from the first appliance 10 a . Here, the second appliance 10 b has a shorter height. The heights can continue to differ throughout the sequence of appliances indicating an order. It may be appreciate that the overall height of the appliance may differ or the height of specific portions of the appliance may differ through the sequence.
FIGS. 6A-6B illustrate the addition of notches or cutouts 56 in each appliance 10 to indicate a sequence or order. The cut outs may be of any size, shape, orientation, or number forming any pattern. Further, the cut outs may be located on an edge 48 of the appliance 10 or on any surface, including an occlusal surface 46 . FIG. 6A illustrates a first appliance 10 a having a first cut out 56 a . The first cut out 56 a has a rectangular shape and is located near an edge 48 . FIG. 5B illustrates a second appliance 10 b having a second cut out 56 b so that the cut out pattern of the first appliance 10 a differs from that of the second appliance 10 b . Here, the second cut out 56 b also has a rectangular shape and is located near the edge 48 adjacent to the first cut out 56 a . The cut out patterns can continue to differ throughout the sequence of appliances indicating an order.
FIGS. 7A-7C illustrate a change in color, such as a hue, gradation of hues, shade, tint or intensity, for each appliance 10 to indicate a sequence or order. For example, the appliances 10 may appear darker or lighter in color through the series, such as ranging from dark red to light pink or vice versa. Or, the sequence may follow the color of the rainbow, such as red, orange, yellow, green, etc. Or, the sequence may follow any other prescribed order of colors. FIG. 7A illustrates a first appliance 10 a having a first color 60 a . FIG. 7B illustrates a second appliance 10 b having a second color 60 b so that the color of the first appliance 10 a differs from that of the second appliance 10 b . The color changes can continue to differ throughout the sequence of appliances indicating an order. It may be appreciated that the appliances 10 a , 10 b may have the color over their entirety, as shown, or the appliances may be colored in some areas and not in others. Or multiple colors may be used on a single appliance, such as in stripes, blocks or various shapes. The color may be embedded in the appliance, such as with the use of a colored plastic rather than the typical clear plastic. Or, the color may be in the form of a dissolvable dye which dissolves in contact with air, such as upon removal from a package, or contact with liquid, such as when rinsed with water or placed in the patient's mouth. Alternatively, as illustrated in FIG. 7C , the color may be present in a peel-away wrapper 62 . The colored wrapper 62 may be attached to the appliance 10 by lamination or other methods. In this example, the wrapper 62 covers the occlusal surfaces 46 of the appliance 10 , however any portion of the appliance 10 may be covered. When the appliance 10 is to be used, the wrapper 62 is peeled away, as shown, and removed. In this way, the appliances may be ordered by color but worn in a transparent state.
Alternatively or in addition, the patient may be provided with individual appliances in the order in which they should be used. To provide such ordering while allowing the appliances to be stored and distributed to the patient in the correct sequence with minimal attention from the orthodontic practitioner, a method may be used in which the appliances are delivered by mail in a specific sequence. FIG. 8 illustrates an embodiment of such a method. As shown, the appliances 10 are individually packaged so that a first package 80 contains a first appliance, a second package 82 contains a second appliance, a third package 84 contains a third appliance, etc. The packages 80 , 82 , 84 are sent through the mail or any delivery system so that they are delivered to the patient P according to a desired schedule. For example, the first package 80 is delivered to the patient P at day 1, the second package 82 is delivered at day 7, the third package 84 is delivered at day 14, etc. It may be appreciated that the individual packages may alternatively be comprises of series of appliances, such as subsets of the entire series of the treatment plan. In such a case, the patient P is delivered a package of appliances 10 at each interval, wherein each package includes a series of appliances. The series may itself also be ordered by any given system, including any of those mentioned above.
FIG. 9 illustrates one appliance 10 of a series of appliances wherein the appliance 10 includes a readable element 100 embedded in the appliance 10 . Alternatively, the readable element 100 may be affixed to the appliance 10 or to a package enclosing the appliance. The readable element 100 may comprise a chip, a bar code or other element that is computer readable, including identification by wireless means, including radiofrequency (rf) identification. When a reader 102 passes over the element 100 , the reader 102 translates the information into a word, symbol or other identifying feature. When translated into a word, the word may include, “first”, “second”, “third”, or “last” to name a few. Also, the word may be in any language, including English, Spanish, French, German, Japanese, etc. The word or identifying feature may be auditory, such as a recording or generation of a spoken voice, or visual, such as a print display. Alternatively, the feature may be transmitted by tactile means, such as by vibration.
FIG. 10 illustrates a series of packages 12 , each package 12 including at least one appliance 10 . Affixed to or incorporated in each package 12 is a label 100 . The label 100 includes at least one non-numeric indicia. For example, a first package 102 shows a label 100 having a series of numbers wherein one number is marked, in this case stamped with a colored dot 103 . This indicates which appliance 10 the first package 102 contains in the treatment sequence. It may be appreciated that the number can be marked with any symbol by any method, including removing the number by erasure, punch-out or notching. It may also be appreciated that other symbols may be used other than numbers, wherein one of the symbols is marked. This is illustrated in a second package 104 which shows such a label 100 . A third package 106 shows a label 100 having a series of symbols, such as shapes, in this case, triangles 120 . The symbols themselves or the color, number, or arrangement may indicate which appliance 10 the third package 106 contains in the treatment series. It may be appreciated that such symbols may include stripes, as illustrated on a fourth package 108 which shows such a label 100 . The stripes may be human readable or computer readable, such as a barcode.
FIG. 11 illustrates an embodiment of a package of dental appliances comprising a package 12 including a plurality of dental appliances 10 positioned in an arrangement within the package 12 which indicates an order of usage. In this embodiment, the arrangement comprises stacking of the appliances.
Although the foregoing invention has been described in some detail by way of illustration and example, for purposes of clarity of understanding, it will be obvious that various alternatives, modifications and equivalents may be used and the above description should not be taken as limiting in scope of the invention which is defined by the appended claims. | The present invention provides systems and methods for providing dental appliances, particularly orthodontic appliances, to a patient wherein the patient is easily able to determine the order or sequence in which the appliances should be worn. Typically the appliances are to be worn in a particular sequence to provide desired treatment, such as a progressive movement of teeth through a variety of arrangements to a final desired arrangement. | 0 |
This is a continuation of application Ser. No. 124,018, filed Feb. 25, 1980 which was a continuation of application Ser. No. 904,730 filed May 11, 1978 both now abandoned.
BACKGROUND OF THE INVENTION
This invention provides an improved method and apparatus for controlling temperatures within streams of molten material in furnace assemblies. In particular, this invention addresses the problem of thermal lags within the material and variations in the temperature of material entering the various sections of such molten stream. While this invention has application to many different processes, for the purpose of illustration, this control system will be described with respect to its application in the glass fiber production process.
The furnace of the glass fiber production process traditionally melts glass batch or cullet in a melting and refining tank. From the melting and refining tank, the molten glass flows into the forehearth section of the furnace. The forehearth section is comprised of numerous channels which supply streams of molten glass to one or more producing devices such as bushings or spinners. These devices attenuate the glass into staple fibers, continuous strands, or other products through conventional processes.
The quality of the glass fibers attenuated in such a process is highly dependent on proper control of the temperature of the glass stream as it passes through the channels of the forehearth to the producing devices. These forehearth channels have traditionally been divided into a number of successive heating zones, each with individual temperature sensing and heat control equipment. The molten glass enters the forehearth section at a temperature of roughly 2500° F., and should generally be delivered to the producing devices at temperatures near 2300° F. for optimal production efficiency. The degree of difficulty involved in this task is further compounded in that the geometric configuration of traditional forehearth assemblies dictate that different streams of glass must often traverse greatly different distances in the course of their normal flow from the melter and refiner exit, through the successive forehearth zones, to their respective producing assembly.
One traditional approach to forehearth temperature control assigns a single temperature regulator to each forehearth zone. This regulator responds to changes in the temperature of a single temperature transducer in the hot gases above the stream of molten glass in the forehearth channel by controlling the fuel-air supply to the burners associated with that particular forehearth section. In general, it has not proved difficult to control such an atmospheric temperature which is sensed by a single transducer in the hot exhaust gases above its associated forehearth zone. The major drawback in such a system is that it is not well adapted to control the temperatures within the molten stream of glass being conveyed to the producing devices of the forehearth. Instead, this system focuses on the control of temperatures in the hot exhaust gases which is seldom effective in adequately controlling the characteristics of the glass which affect production efficiency.
A more recent control method is one such as that disclosed in the patent to Griem Jr., U.S. Pat. No. 3,506,427, issued Apr. 14, 1970. This patent discloses a technique for compensating temperature control in forehearth zones for masses of unmelted glass batch passing through the channels of the forehearth. In this technique, each forehearth zone's temperature controller responds directly to a temperature measurement within the glass of that particular zone by adjusting the heat input of said zone to achieve a desired glass temperature. In order to dampen response of such controllers to cool masses of glass passing through the individual forehearth zones, Griem suggests that such masses be detected upon entrance to the forehearth and effectively tracked in their journey through the forehearth channels, compensating each zone's controller as its associated temperature transducer becomes affected by the cool mass. One difficulty with this technique is that this compensation consists primarily of deactivation of the control mechanism for the particular forehearth zone. Another difficulty is that no consideration has been devoted to the thermal lags which occur in the stream of molten glass between the heating mechanism and the temperature transducer.
Another system for controlling the temperature in molten glass is in U.S. Pat. No. 4,028,083 which discloses a furnace, which includes a melting and refining tank and a forehearth, is divided into a plurality of zones or regions. Each of the zones is provided with means for sensing temperature within the zone and a means for heating the zone. Means is also provided for measuring the individual heat input into the furnace of the heating means in each of the zones. When changes in temperatures are required, the temperatures in the different zones of the furnace are controlled by adjusting the heat input of the heating means in at least one of the zones to cause the temperatures in each of the zones where changes in temperature are required to approach desired temperatures. The adjustment is made in response to the last sensed temperature in a time period for each of the zones and in response to at least some of the temperatures sensed and the heat inputs measured in each of zones during that time period so as to compensate for thermal lags within the furnace and the effect of heat input in any one of the zones on the temperatures in other of the zones. However, difficulties were experienced in trying to adapt that system to forehearth control of the type disclosed in this application.
A system to control the temperatures in a forehearth must account for at least two important characteristics of the forehearth. First, there exists a thermal lag between a change in the heat input of a set of burners and changes in the temperature of the stream of molten glass in the associated forehearth zone. In addition, the temperature of the stream of glass in one zone of the forehearth will affect future temperatures in the glass streams of successive forehearth zones as the glass continues its flow to the producing devices. It is an object of the present invention to overcome the problems associated with the control techniques of the prior art by accounting for both thermal lags in the forehearth glass streams and the movement of the molten glass as it travels from the forehearth inlet through the forehearth channels to the producing devices.
In this invention, accurate control of molten glass temperatures in the streams of forehearth assemblies is achieved by dividing the forehearth into zones or regions wherein each zone is provided with a means for heating the molten glass within the zone, a means for controlling the amount of heat provided by the heating means, and a means for sensing at least one temperature in each zone. To implement the control of the molten glass temperature in a forehearth zone, the current temperature of the molten glass for such zone and the current atmospheric temperature for such zone are sensed and recorded and the current temperature of the molten glass in the immediately preceding zone is sensed. If the temperature of the molten glass in such zone is not within an acceptable range, such as 1° F., of the desired molten glass temperature, the heat input of the heating means for the corresponding forehearth zone is adjusted to cause the temperature in said zone to approach the desired molten glass setpoint temperature. This adjustment is made in response to the last sensed temperature in said zone, the history of the molten glass temperatures in such zone, the atmospheric temperature in said zone and the history of the atmospheric temperatures in such zone, and the molten glass temperature in the preceding forehearth zone so as to compensate for thermal lags within the molten streams of the forehearth assembly and the movement of the molten glass as it travels to the producing devices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view from the bottom of a glass melting tank, the conditioning channels and the forehearth legs;
FIG. 2 is a schematic view in cross-section of the conditioning channels; and,
FIG. 3 is a schematic view in cross-section of one of the forehearth legs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a forehearth 2 which includes a number of conditioning channels 4a, 4b, 4c, and 4d. The moten glass is conveyed in a stream from the melter 6 to the channels and on to the forehearth legs 8a, 8b, 8c, 8d, 8e, 8f, 8g, and 8h.The forehearth legs are constructed in a manner to convey the molten stream to the producing devices 10a, 10b, 10c, 10d, 10e, 10f, 10g, 10h and 10i.
FIG. 2 is a cross-sectional breakaway pictorial of the same forehearth assembly. The glass flows through the channels 4a, 4b, 4c, and 4d to the forehearth legs 8a, 8b, etc. Each channel section is segmented as an individual heat control zone, and each forehearth leg has been arbitrarily segmented into two (2) individual heat control zones 12a and 12b. Each zone is heated by a multiplicity of gas or oil fired burners 14a and 14b. The heat input to the forehearth for each zone is controlled by conventional fuel-flow regulators 16a and 16b; e.g., remotely controlled valve control motors. These fuel-flow regulators control the fuel-air supply to each set of burners by adjusting the settlings of the supply valves 18a and 18b. Each zone is provided with at least one atmospheric temperature sensing means such as thermocouples 20a and 20b located adjacent the roof of the zone which measures the zone temperature in the hot exhaust gases above the stream of glass. Each zone is also provided with at least one temperature transducer 22a and 22b located adjacent the floor of the zone which measures the zone temperature within the stream of molten glass for that particular zone.
The regulators 16a and 16b typically regulate the amount of fuel-air supplied to the burners 14a and 14b in response to an atmospheric temperature setpoint signal and the measurement signal from thermocouples 20a and 20b. Alternately, regulators 16a and 16b may regulate the amount of fuel-air supplied to burners 14a and 14b in response to a flow setpoint singal and the measurement from flow transducers (not shown). In this latter technique, it is also possible to adjust the flow setpoint signal using a conventional BTU analyzer (e.g., an analyzer marketed under the trade name REINEKE calorimeter) in order to control the BTU or heat input into the forehearth to a desired setpoint value.
FIG. 3 presents a segmented cross-sectional view of an individual forehearth leg. The molten stream of glass enters the forehearth leg 8a from adjacent channel 4a. The forehearth leg 8a is further divided into two (2) separate control zones, 12a and 12b. A certain amount of the glass entering control zone 12a passes into the producing devices 10a, 10b, 10c, and 10d where it is attenuated into glass fibers. The remaining glass flow continues to control zone 12b where it is attenuated into glass fibers at producing devices 10e, 10f, 10g, 10h and 10i.
Although a gas or oil fired forehearth has been presented for the purpose of illustrating this invention, any number or means and methods for supplying and controlling the BTU input or heat energy input to zones can be utilized. For example, this invention would apply equally well to furnaces heated by electrodes or similar heating means.
The control system for a forehearth such as the one illustrated in FIGS. 1, 2, and 3 will be discussed in detail. It should be noted that the same control system can be used with any multi-zone forehearth assembly.
The temperature being regulated in each zone of the forehearth is affected by the BTU or heat input of the burners for that zone. It is important to note that this molten glass temperature does not respond instantaneously to changes in the heat input to the zone. Rather, there is a thermal lag associated with the response of a temperature transducer on the floor of zone to a change in the rate of heat input to that zone. In addition, the temperature within the stream of molten glass within any one zone is affected by the temperature of the molten glass entering said zone from the immediately preceding zone. In relation to the first zone 12a, the temperature of the immediately preceding zone is sensed by temperature transducer 24a in channel 4a. Similar temperature transducers 24b, 24c and 24d are located in channels 4b, 4c and 4d.
The control system of the present invention requires separate data acquisition and control means for each zone of the forehearth assembly. The data acquired for each zone consists of individual temperature measurements made by the temperature transducers 22 for both the zone itself and the immediately preceding zone and the atmospheric temperature for the particular zone. While this data can be collected continuously or at shorter intervals, the data is normally acquired every time a new control action is computed for the control system of the individual zone. The temperature of the molten glass and the atmospheric temperature for the zone are fed to a storage device for a period of time. Consequently, just prior to the generation of a new control signal, the storage device has available the current temperature of the molten glass stream in the zone, the current atmospheric temperature in the zone, the current temperature of the molten glass stream in the immediately preceding zone, and a history of the molten glass temperatures and the atmospheric temperatures over a period of time. This data is mathematically weighed to generate a control signal which is used for the atmospheric temperature set point for the individual forehearth zone. This control signal is sent to the individual regulator 16 for this particular forehearth zone. This control signal is also routed to the data storage device to become part of the historical data on the control signals for this individual forehearth zone.
The mathematical weighing of the data from the storage device for an individual forehearth zone to obtain the control signal for the setpoint for the atmospheric temperature above the molten glass in the zone is preferably accomplished according to the following mathematical relationship: ##EQU1## where: u a (t) is the setpoint signal for the atmospheric temperature in this particular control zone at time t
u 0 is the nominal atmospheric temperature for this forehearth zone about which the performance of this zone has been linearized
e is some contant data acquisition interval (e.g., 5 minutes)
s(t) is the temperature sensed in the molten glass stream in this forehearth zone at time t
s 0 is the temperature in the molten glass stream of this forehearth zone about which the performance of this zone has been linearized
n is an integer sufficiently large to account for the effects of thermal lags within the stream of molten glass in this zone.
a,b,c k , and d are scalar variables obtained by one of several feedback control approaches. In general, these values are determined from the A and B matrices defined below.
w(t) is the differenc between the temperature of the molten glass stream in the immediately preceding zone and the desired molten glass temperature in this particular zone.
z(t) is the sum of the differences between s(t) and s 0 in all previous control actions.
To obtain the A and B matrices referred to above, a mathematical model which successfully accounts for thermal lags within the molten streams and the movement of molten glass toward the producing devices has been developed. The preferred linearized model of the present invention is in the form:
x(t+e)-x.sub.0 =Ax(t)-Ax.sub.0 +Bu.sub.a (t)-Bu.sub.0 +Cw(t)
where:
e is the same constant data acquisition interval defined above
x(t) is a state vector (column vector) composed of the temperature sensed in the molten glass stream in this forehearth zone at time t and each of the u a (.) for the preceding n control actions
u a (t) is as described above
x 0 is a constant version of the state vector about which system performance has been linearized
u 0 is as described previously
A is a constant matrix determined from the above model. In the case when n=1, A is 2×2.
B is a constant matrix determined from the above model. In the case when n=1, B is 2×1.
C is a constant matrix determined from the above model. It will have the same order as the B matrix.
The A, B, and C matrices are selected to make historical data satisfy the above model. The determination of values for the individual elements of A, B, and C can be made from the deterministic relationships involving knowledge of the forehearth structure or from stochastic models based on historical data on forehearth performance. In general many techniques for determining these matrices are available. It is not intended to restrict this invention to any one particular technique.
Once A, B, and C are determined, these matrices are used to compute a,b,c k , and d. The preferred technique of this invention is linear optimal control theory with a quadratic perfomance index, but the techniques of stabilization theory and modal control will work equally well.
The present invention is not limited to the preferred present embodiment disclosed in detail. Other known mathematical techniques can be applied to generate essentially the same control actions. Also, other variables such as production rate can be introduced into this invention for the purpose of adjusting control to compensate for changes in such variables. | A forehearth through which molten glass flows is divided into a plurality of zones. Means are provided in each zone for measuring the temperature of the molten glass and the atmospheric temperature. Means are provided for accumulating and storing data. When the temperature of the molten glass in a selected zone is not within an acceptable range a control signal is generated. The control signal is in response to the current molten glass and atmospheric temperatures in the zone, the current molten glass temperature in the immediately preceding zone and the accumulated and stored data comprising the history of the molten glass and atmospheric temperatures for the selected zone. | 8 |
TECHNICAL FIELD
[0001] This invention relates to roofing shingles. More particularly, this invention relates to roofing shingles manufactured with more efficient use of raw materials.
BACKGROUND OF THE INVENTION
[0002] A common method for the manufacture of asphalt shingles is the production of a continuous strip of asphalt shingle material followed by a shingle cutting operation which cuts the material into individual shingles.
[0003] In the production of the continuous strip of asphalt shingle material, a substrate such as an organic felt or a glass fiber mat is passed into contact with a coater containing liquid asphalt to form a tacky asphalt coated strip. Subsequently, the hot asphalt coated strip is passed beneath one or more granule applicators which apply the protective surface granules to portions of the asphalt coated strip to form a granule coated sheet. The granule coated sheet is cooled and subsequently cut into individual shingles.
[0004] In the manufacturing process, the asphalt coated strip is conceptually divided into an equal number of prime lanes, and headlap lanes. The prime lanes receive an application of prime granules while the headlap lanes receive an application of headlap granules. It would be advantageous if shingles could be manufactured with more efficient use of raw materials.
SUMMARY OF THE INVENTION
[0005] The above objects as well as other objects not specifically enumerated are achieved by a method of manufacturing roofing shingles. The method comprises the steps of: coating a continuously supplied shingle mat with roofing asphalt to make an asphalt-coated sheet, the asphalt-coated sheet having at least one prime portion and at least one headlap portion, varying the thickness of the asphalt-coated sheet such that the at least one prime portion of the asphalt-coated sheet has a first thickness and the headlap portion has a second thickness, the thickness of the asphalt-coated sheet being varied by passing the asphalt-coated sheet through compression rollers, applying granules onto the asphalt-coated sheet to form a granule-covered sheet, and cutting the granule-covered sheet into shingles.
[0006] According to this invention there is also provided a method of manufacturing roofing shingles. The method comprises the steps of: coating a continuously supplied shingle mat with roofing asphalt to make an asphalt-coated sheet, the asphalt-coated sheet having at least one prime portion and at least one headlap portion, varying the thickness of the asphalt-coated sheet such that the at least one prime portion of the asphalt-coated sheet has a first thickness and the headlap-portion has a second thickness, the thickness of the asphalt-coated sheet being varied by passing the asphalt-coated sheet under an auxiliary coater, applying granules onto the asphalt-coated sheet to form a granule covered sheet, and cutting the granule-covered sheet into shingles.
[0007] According to this invention there is also provided a method of manufacturing roofing shingles. The method comprises the steps of: coating a continuously supplied shingle mat with roofing asphalt to make an asphalt-coated sheet, the asphalt-coated sheet having at least one prime portion and at least one headlap portion, varying the thickness of the asphalt-coated sheet such that the at least one prime portion of the asphalt-coated sheet has a first thickness and the headlap portion has a second thickness, applying a film to the at least one headlap portion of the asphalt-coated sheet, applying granules onto the at least one prime portion of the asphalt-coated sheet, and cutting the sheet into shingles.
[0008] According to this invention there is also provided an apparatus for manufacturing roofing shingles, the roofing shingles having at least one prime portion and at least one headlap portion. The apparatus comprises an asphalt coater configured to receive a shingle mat traveling in a machine direction. The asphalt coater is configured to coat the shingle mat with asphalt. At least one compression roller is positioned downstream from the asphalt coater. The at least one compression roller is configured to receive and compress the asphalt-coated sheet to the extent that excess asphalt is squeezed from the asphalt-coated sheet and the at least one prime portion of the asphalt-coated sheet forms a first thickness and the headlap portion forms a second thickness. At least one granule blender is positioned downstream from the at least one compression roller. The at least one granule blender is configured to apply granules onto the asphalt-coated sheet. A drum is positioned downstream from the at least one granule blender. The drum is configured to press the granules into the granule-covered sheet and remove the granules which are not adhered to the granule-covered sheet. A cutter is positioned downstream from the at least one granule blender. The cutter is configured to cut the granule-covered sheet into shingles.
[0009] According to this invention there is also provided an apparatus for manufacturing roofing shingles, the roofing shingles having at least one prime portion and at least one headlap portion. The apparatus comprises an asphalt coater configured to receive a shingle mat traveling in a machine direction. The asphalt coater is configured to coat the shingle mat with asphalt. At least one auxiliary coater is positioned downstream from the asphalt coater. The at least one auxiliary coater is configured to receive the shingle mat traveling in the machine direction and impart additional asphalt material onto the shingle mat such that the at least one prime portion of the asphalt-coated sheet forms a first thickness and the headlap portion forms a second thickness. At least one granule blender is positioned downstream from the at least one auxiliary coater. The at least one granule blender is configured to apply granules onto the asphalt-coated sheet. A drum is positioned downstream from the at least one granule blender. The drum is configured to press the granules into the granule-covered sheet and remove the granules which are not adhered to the granule-covered sheet. A cutter is positioned downstream from the at least one granule blender. The cutter is configured to cut the granule-covered sheet into shingles.
[0010] According to this invention there is also provided an apparatus for manufacturing roofing shingles, the roofing shingles having at least one prime portion and at least one headlap portion. The apparatus comprises an asphalt coater configured to receive a shingle mat traveling in a machine direction. The asphalt coater is configured to coat the shingle mat with asphalt. At least one compression roller is positioned downstream from the asphalt coater. The at least one compression roller is configured to receive and compress the asphalt-coated sheet to the extent that excess asphalt is squeezed from the asphalt-coated sheet and the at least one prime portion of the asphalt-coated sheet forms a first thickness and the headlap portion forms a second thickness. At least one film application unit is positioned downstream from the at least one compression roller. The at least one film application unit is configured to receive the shingle traveling in the machine direction and apply a film to the at least one headlap portion of the asphalt-coated sheet. At least one granule blender is positioned downstream from the at least one film application unit. The at least one granule blender is configured to apply granules onto the asphalt-coated sheet. A drum is positioned downstream from the at least one granule blender. The drum is configured to press the granules into the granule-covered sheet and remove the granules which are not adhered to the granule-covered sheet. A cutter is positioned downstream from the at least one granule blender. The cutter is configured to cut the granule-covered sheet into shingles
[0011] According to this invention there is also provided a method of manufacturing roofing shingles. The method comprises the steps of: coating a continuously supplied shingle mat with roofing asphalt to make an asphalt-coated sheet, the asphalt-coated sheet having at least one prime portion and at least one headlap portion, passing the asphalt-coated sheet through a thickness control mechanism such that the at least one prime portion of the asphalt coated-sheet has a prime portion weight and the headlap portion has a headlap portion weight, measuring the weight of the at least one prime portion and the at least one headlap portion in both the machine direction and the cross machine direction downstream from the thickness control mechanism, adjusting the thickness control mechanism to control the weight of the asphalt-coated sheet to achieve a desired weight, applying granules onto the at least one prime portion of the asphalt-coated sheet, and cutting the granule-covered sheet into shingles.
[0012] Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the invention, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic elevational view, partially in cross section, of a portion of an apparatus for making shingles according to the method of the invention.
[0014] FIG. 2 is a schematic plan view of a portion of the apparatus illustrated in FIG. 1 , taken along the line 2 - 2 , showing a portion of the asphalt-coated sheet.
[0015] FIG. 3 is a side elevational view of the compression rolls, taken along the line 3 - 3 , of FIG. 1 .
[0016] FIG. 4 is a side elevational view, in cross-section, of the asphalt-coated sheet downstream from the compression rolls of FIG. 3 .
[0017] FIG. 5 is a plan view, in elevation, of a shingle according to one embodiment of the invention.
[0018] FIG. 6 is a side elevational view, in cross-section, of the shingle of FIG. 5 .
[0019] FIG. 7 is a schematic elevational view, partially in cross section, of a second embodiment of an apparatus for making shingles, the apparatus having an auxiliary coater.
[0020] FIG. 8 is a side elevational view of the compression rolls, taken along the line 8 - 8 , of FIG. 7 .
[0021] FIG. 9 is a side elevational view, in cross-section, of the asphalt-coated sheet downstream from the compression rolls of FIG. 8 .
[0022] FIG. 10 is a schematic elevational view, partially in cross section, or a third embodiment of an apparatus for making shingles, the apparatus having an asphalt removal unit.
[0023] FIG. 11 is a side elevational view of the compression rolls, taken along the line 11 - 11 , of FIG. 10 .
[0024] FIG. 12 is a side elevational view, in cross-section, of the asphalt-coated sheet downstream from the compression rolls of FIG. 10 .
[0025] FIG. 13 is a schematic elevational view, partially in cross section, of a fourth embodiment of an apparatus for making shingles, the apparatus having a laminator.
[0026] FIG. 14 is a side elevational view of the compression rolls, taken along the line 14 - 14 , of FIG. 13 .
[0027] FIG. 15 is a side elevational view, in cross-section, of the asphalt-coated sheet downstream from the compression rolls of FIG. 13 .
DETAILED DESCRIPTION OF THE INVENTION
[0028] Composite shingles, such as asphalt shingles, are a commonly used roofing product. Asphalt shingle production generally includes feeding a base material from an upstream roll and coating it first with a filled roofing asphalt material, then a layer of granules. The base material is typically made from a fiberglass mat provided in a continuous shingle membrane or sheet. It should be understood that the base material can be any suitable support material.
[0029] The filled roofing asphalt material is added to the continuous shingle membrane for strength and improved weathering characteristics. It should be understood that the filled roofing asphalt material can include any suitable material, preferably low in cost, durable, and resistant to fire.
[0030] Composite shingles typically have a headlap region and a prime region. The headlap region may be ultimately covered by adjacent shingles when installed upon a roof. The prime region will be ultimately visible when the shingles are installed upon a roof.
[0031] The granules deposited on the composite material shield the filled roofing asphalt material from direct sunlight, offer resistance to fire, and provide texture and color to the shingle. The granules generally involve at least two different types of granules. Headlap granules are applied to the headlap region. Headlap granules are relatively low in cost and primarily serve the functional purposes of protecting the underlying asphalt material, balancing sheet weight and preventing overlapping shingles from sticking to one another. Colored granules or other prime granules are relatively expensive and are applied to the shingle at the prime regions. Prime granules are disposed upon the asphalt strip for both the functional purpose of protecting the underlying asphalt strip and for the purpose of providing an aesthetically pleasing appearance of the roof.
[0032] The layers of granules are typically applied with one or more granule applicators, such as pneumatic blenders, to the asphalt material covering the continuous shingle membrane. The pneumatic blender is a type of granule applicator known in the art. The granules can be applied to the continuous shingle membrane in color patterns to provide the shingles with an aesthetically pleasing appearance. The granules optionally can include anti-microorganism granules, such as copper granules, to inhibit the growth of algae, fungus, and/or other microorganisms.
[0033] The description and drawings disclose a method for manufacturing an asphalt shingle having a variable thickness. Referring now to the drawings, there is shown in FIG. 1 an apparatus 10 for manufacturing asphalt-based shingles according to the invention. The illustrated manufacturing process involves passing a continuous sheet in a machine direction (indicated by an arrow 12 ) through a series of manufacturing operations. The sheet usually moves at a speed from about 300 feet/minute to about 800 feet/minute. However, other speeds can be used.
[0034] In a first step of the manufacturing process, a continuous sheet of shingle mat 14 is payed out from a roll (not shown). The shingle mat 14 can be any type of substrate known for use in reinforcing asphalt-based roofing shingles, such as a nonwoven web of glass fibers. The shingle mat 14 is fed through a coater 16 where a coating of asphalt 18 is applied to the top and bottom of the shingle mat 14 . The asphalt coating 18 can be applied in any suitable manner. In the illustrated embodiment, the shingle mat 14 contacts a supply of hot, melted asphalt 18 to completely cover the shingle mat 14 with a tacky coating of asphalt 18 . However, in other embodiments, the asphalt coating 18 could be sprayed on, rolled on, or applied to the shingle mat 14 by other means. Typically the filled roofing asphalt material is highly filled with a ground mineral filler material, amounting to at least about 60 percent by weight of the asphalt/filler combination. The shingle mat 14 exits the coater 16 as an asphalt-coated sheet 20 . The asphalt coating 18 on the asphalt-coated sheet 20 remains hot.
[0035] The asphalt-coated sheet 20 is shown in more detail in FIG. 2 . As shown, the asphalt-coated sheet 20 for the three-wide apparatus 10 comprises six distinct regions or lanes including three headlap lanes h 1 , h 2 , and h 3 , and three prime lanes p 1 , p 2 , and p 3 . An exemplary roofing shingle is shown by a phantom line 22 and may be cut from asphalt-coated sheet 20 as shown. In this manner, three roofing shingles of any length desired may be cut from each such length of asphalt-coated sheet 20 . Each shingle 22 would contain one headlap lane h 1 , h 2 , or h 3 , and one respective adjacent prime lane p 1 , p 2 , or p 3 . Accordingly, the shingle 22 includes a headlap region 26 and a prime region 24 .
[0036] The headlap region 24 of the shingle 22 is that portion which is covered by adjacent shingles when the shingle 22 is ultimately installed upon a roof. The prime region 26 of the shingle 22 is that portion which remains exposed when the shingle 22 is ultimately installed upon a roof.
[0037] In this embodiment, the shingle 22 is cut from the asphalt-coated sheet 20 to be approximately three feet long by one foot wide. As further shown in FIGS. 2 and 6 , the shingle 22 includes two cut-out regions 28 which define three tabs 30 . It will be apparent to one skilled in the art that the asphalt-coated sheet 20 may be manufactured having a wide variety of widths to allow different numbers of shingles to be cut therefrom. For example, some roofing shingle manufacturing plants use an asphalt-coated sheet (not shown) which is sufficiently wide to allow four or more one-foot wide shingles to be cut therefrom. Such a wider asphalt-coated sheet would include an additional headlap region, and an additional prime region. One skilled in the art will also recognize that roofing shingles of different sizes, i.e. roofing shingles having different lengths and/or widths, may be cut from the asphalt-coated sheet 20 .
[0038] As will be appreciated by one skilled in the art, while the Figures illustrate a 3-tab strip shingle such as that shown in FIG. 5 and process/apparatus for manufacturing such a strip shingle, the same principles may be applied to a laminated shingle; i.e. the headlap portion of the laminate shingle may be thinner than the tab region, or vice-versa. Furthermore, any of the overlay and/or underlay and/or headlap regions of the laminated shingle may be thinned according the principles of the instant invention to accomplish reduction of asphalt in unnecessary regions. In one such embodiment, the instant invention is used to remove excess asphalt from between the layers of the laminated region of the shingle in the exposed area of the laminate shingle.
[0039] The resulting asphalt-coated sheet 20 , including headlap lanes h 1 , h 2 and h 3 and prime lanes, p 1 , p 2 and p 3 , is then passed between a top compression roll 32 and a bottom compression roll 34 . In this embodiment, the top compression roll 32 is a drum rotating about axis a 1 . Similarly, the bottom compression roll 34 is a drum rotating about axis a 2 . Referring again to FIG. 1 , as the asphalt-coated sheet 20 feeds between the top compression roll 32 and the bottom compression roll 34 , the asphalt-coated sheet 20 is compressed and excess asphalt is squeezed from the asphalt-coated sheet 20 . The excess asphalt is the returned to the coater 16 . In an alternative embodiment (not shown), the compression rolls 32 , 34 are provided at the applicator 18 , versus the downstream position as shown in the Figures, thereby eliminating a set of rollers.
[0040] As shown in FIG. 3 , the top compression roll 32 comprises different roll regions having different roll diameters that correspond to the headlap and prime lanes of the asphalt-coated sheet 20 . In this embodiment, the top compression roll 32 includes roll regions 40 , 42 and 44 . Roll region 40 has a roll diameter d 1 , roll region 42 has a roll diameter d 2 and roll region 44 has a roll diameter d 3 . The top compression roll 32 also includes roll regions 46 , 48 and 50 . Roll region 46 has a roll diameter d 4 , roll region 48 has a roll diameter d 5 and roll region 50 has a roll diameter d 6 .
[0041] In this embodiment as further shown in FIG. 3 , the bottom compression roll 34 has a bottom roll region 52 . The bottom roll region 52 extends across the entire width of the roll 34 . The bottom roll region 52 has a bottom roll diameter b 1 .
[0042] In operation, as the asphalt-coated sheet 20 passes between the top compression roll 32 and the bottom compression roll 34 , headlap lane h 1 of the asphalt-coated sheet 20 passes between roll region 40 of the top compression roll 32 and roll region 52 of the bottom compression roll 34 . As the headlap lane h 1 passes between roll region 40 of the top compression roll 32 and roll region 52 of the bottom compression roll 34 , headlap lane hl is compressed to thickness t 1 . In a similar manner, as headlap lanes h 2 and h 3 pass between roll regions 42 and 44 of the top compression roll 32 and roll region 52 of the bottom compression roll 34 , headlap lanes h 2 and h 3 are compressed to thicknesses t 2 and t 3 , respectfully. Also in a similar manner, as prime lanes p 1 , p 2 and p 3 pass between roll regions 46 , 48 and 50 of the top compression roll 32 and roll region 52 of the bottom compression roll 34 , prime lanes p 1 , p 2 and p 3 are compressed to thicknesses t 4 , t 5 and t 6 , respectfully. In this embodiment as shown in FIG. 3 , the d 1 , d 2 and d 3 diameters of roll regions 40 , 42 and 44 , corresponding to headlap lanes h 1 , h 2 and h 3 , are the same. In another embodiment, the d 1 , d 2 and d 3 diameters of roll regions 40 , 42 and 44 could be different. Similarly, in this embodiment as shown in FIG. 3 , the d 4 , d 5 and d 6 diameters of roll regions 46 , 48 and 50 , corresponding to prime lanes p 1 , p 2 and p 3 , are the same. In another embodiment, the d 4 , d 5 and d 6 diameters of roll regions 46 , 48 and 50 could be different.
[0043] While the top compression roll 32 shown in FIG. 3 illustrates various diameters d 1 , d 2 , d 3 , d 4 , d 5 and d 6 and the bottom compression roll 34 illustrates a constant diameter b 1 , in another embodiment the top compression roll 32 can have a constant diameter and the bottom compression roll 34 can have various diameters.
[0044] The asphalt-coated sheet 20 exits from the top compression roll 32 and the bottom compression roll 34 as a formed sheet 54 as shown in FIG. 4 . Formed sheet 54 includes headlap lanes h 1 , h 2 and h 3 having thicknesses t 1 , t 2 and t 3 , respectfully. Formed sheet 54 also includes prime lanes p 1 , p 2 and p 3 having thicknesses t 4 , t 5 and t 6 , respectfully. In this embodiment, thicknesses t 1 , t 2 and t 3 are in a range from about 20 mils to about 70 mils. Alternatively, the thicknesses t 1 , t 2 and t 3 could be more than 70 mils or less than 20 mils. In this embodiment, thicknesses t 4 , t 5 and t 6 are in a range from about 40 mils to about 100 mils. Alternatively, the thicknesses t 4 , t 5 and t 6 could be more than 100 mils or less than 40 mils.
[0045] As shown in FIGS. 5 and 6 , after the roofing shingle 22 has been cut from the formed sheet 54 , the roofing shingle 22 includes headlap lane h 1 and prime lane p 1 . Headlap lane h 1 has thickness t 1 and prime lane p 1 has thickness t 4 . In this embodiment, the thickness t 1 is thinner than the thickness t 4 . In another embodiment, the thickness tl may be the same as the thickness t 4 or the thickness t 1 may be more than the thickness t 4 . In one embodiment, the difference between the thickness t 1 and the thickness t 4 is at least 1 mil. In another embodiment, the difference between the thickness t 1 and thickness t 4 can be 1 mil or less than 1 mil.
[0046] As previously discussed, compression of the asphalt-coated sheet 20 between the top compression roll 32 and the bottom compression roll 34 squeezes excess asphalt material 18 from the asphalt-coated sheet 20 . In this embodiment, the excess asphalt material 18 is recovered and recycled. By squeezing excess asphalt material 18 from the asphalt-coated sheet 20 , a smaller amount of raw materials is necessary for the manufacture of composite shingles.
[0047] In addition to using a smaller amount of raw materials, the weight of the shingles can be reduced by squeezing excess asphalt material 18 from the asphalt-coated sheet 20 . By reducing the weight of the shingles, the cost of raw materials and transportation of the manufactured shingles will be reduced. The excess asphalt material 18 can be squeezed from the asphalt-coated sheet by a thickness control mechanism. In this embodiment the thickness control mechanism comprises the top compression roll 32 and the bottom compression roll 34 . In another embodiment, the thickness control mechanism can be any other assembly or mechanism sufficient to control the thickness of the asphalt-coated sheet 20 . Referring again to FIG. 4 , the thicknesses t 1 , t 2 , t 3 , t 4 , t 5 and t 6 formed by the top compression roll 32 and the bottom compression roll 34 can be controlled to provide the desired weights of the prime portions 26 and the headlap portions 24 in both the machine direction and the cross machine direction. In one embodiment, a shingle could have a prime portion 26 having a prime portion weight per square foot and a headlap portion 26 having a lesser headlap portion weight per square foot. Referring again to FIG. 1 , as the formed sheet 54 exits the top compression roll 32 and the bottom compression roll 34 , the weight of the formed sheet 54 is measured. The weight of the formed sheet 54 can be determined by any method, such as for example measuring the density of the asphalt using a scanner, suitable to determine the weight of the formed sheet 54 . By measuring the weight of the formed sheet 54 , the measured weight of the formed sheet 54 can be compared to the desired weight of the formed sheet 54 and adjustments, if necessary, can be made to the top and bottom compression rolls 32 and 34 to produce the desired thicknesses t 1 , t 2 , t 3 , t 4 , t 5 and t 6 . It is to be understood that different shingle products can have different desired weights for the prime portions and the headlap portions. While in this embodiment the weight of the formed sheet 54 is determined downstream from the top and bottom compression rolls 32 and 34 respectfully, and it is to be understood that the weight of the shingle can be determined at other locations, such as for example after the granules have been deposited on the formed sheet 54 , in the process.
[0048] An example of a lightweight shingle having varying weight regions is a shingle of the type disclosed in U.S. patent application Ser. No. 11/582,285 filed Oct. 17, 2006, which is hereby incorporated by reference, in its entirety. The disclosed lightweight shingle reduces the overall shingle weight by incorporating low density, lightweight headlap granules into the headlap region. In a preferred embodiment, a lightweight granule is used in combination with a thin headlap as described herein. In yet a further embodiment, the headlap granules are of a larger dimension than the prime granules to accomplish a more uniform overall sheet thickness, and more preferably the headlap granule comprises a lightweight granule.
[0049] Referring again to FIG. 1 , the resulting multi-leveled, asphalt-coated formed sheet 54 is then passed beneath a series of granule applicators, hoppers or blenders 56 and 58 for dispensing granules to an upper surface of the formed sheet 54 . The granule applicators 56 and 58 can be of any type suitable for depositing granules onto the formed sheet 54 . An example of a granule blender is a granule blender of the type disclosed in U.S. Pat. No. 5,599,581 to Burton et al., which is hereby incorporated by reference, in its entirety. Additionally, a granule valve such as the granule valve disclosed in U.S. Pat. No. 6,610,147 to Aschenbeck may also be used. U.S. Pat. No. 6,610,147 to Aschenbeck is also incorporated by reference in its entirety. Although two granule blenders 56 and 58 are shown in the embodiment illustrated in FIG. 1 , any suitable number and configuration of granule blenders can be used.
[0050] For example, a series of two blenders can be used, wherein the granule blender 56 can be used to deposit prime granules 57 on the prime lanes p 1 , p 2 and p 3 . Similarly, the granule blender 58 can be used to apply headlap granules 59 on the headlap lanes h 1 , h 2 and h 3 . Applying prime granules 57 and headlap granules defines a granule-covered sheet 62 . In another embodiment, additional granule blenders can be used for additional granule drops, such as different colors, sharp demarcations and background granules.
[0051] As shown in FIG. 1 , after all the granules are deposited on the asphalt-coated sheet 20 , the granule-covered sheet 62 is turned around a slate drum 64 to press the granules into the asphalt coating and to temporarily invert the granule-covered sheet 62 so that the excess granules fall off. The excess granules are recovered and reused. The granule-covered sheet 62 is subsequently fed through a cutter 74 that cuts the granule-covered sheet 62 into individual shingles 22 . The cutter 74 may be any type of cutter, such as for example a rotary cutter, sufficient to cut the granule-covered sheet 62 into individual shingles 22 .
[0052] In another embodiment, apparatus 110 for manufacturing an asphalt-based roofing shingle is shown in FIG. 7 . An asphalt-coated sheet 120 , including headlap lanes h 1 , h 2 and h 3 and prime lanes, p 1 , p 2 and p 3 , is fed between a top compression roll 132 and a bottom compression roll 134 . In this embodiment, the top compression roll 132 and the bottom compression roll 134 are rotating drums as shown in FIG. 8 . Referring again to FIG. 7 , as the asphalt-coated sheet 120 feeds between the top compression roll 132 and the bottom compression roll 134 , the asphalt-coated sheet 120 is compressed and excess asphalt is squeezed from the asphalt-coated sheet 120 .
[0053] As shown in FIG. 8 , the top compression roll 132 comprises a single roll region 140 having a consistent roll diameter d 100 . Similarly, the bottom compression roll 134 has a single bottom roll region 152 having a consistent bottom roll diameter b 100 .
[0054] Referring again to FIG. 7 , in operation, as the asphalt-coated sheet 120 passes between the top compression roll 132 and the bottom compression roll 134 , the headlap lanes h 1 , h 2 and h 3 of the asphalt-coated sheet 120 , and the prime lanes p 1 , p 2 , and p 3 pass between roll region 140 of the top compression roll 132 and roll region 152 of the bottom compression roll 134 . As the headlap lanes h 1 , h 2 and h 3 and the prime lanes p 1 , p 2 , and p 3 pass between roll region 140 of the top compression roll 132 and roll region 152 of the bottom compression roll 134 , the headlap lanes h 1 , h 2 and h 3 and the prime lanes p 1 , p 2 , and p 3 are compressed to thickness t 100 . In this embodiment, the top compression roll 132 and the bottom compression roll 134 compress the asphalt-coated sheet 120 to a uniform consistent thickness t 100 .
[0055] The asphalt-coated sheet 120 exits the compression of the top compression roll 132 and the bottom compression roll 134 as a formed sheet 154 as shown in FIG. 7 . Formed sheet 154 includes headlap lanes h 1 , h 2 and h 3 and prime lanes p 1 , p 2 and p 3 , each having thicknesses t 100 . The formed sheet 154 passes under an auxiliary coater 170 . In this embodiment, the auxiliary coater 170 is configured to impart additional asphalt material 118 onto the top of the prime lanes p 1 , p 2 , and p 3 of the formed sheet 154 , forming an additional layer 122 , shown in FIG. 9 . After depositing the additional layer 122 of asphalt material 118 on the top of the prime lanes p 1 , p 2 , and p 3 , the formed sheet 154 becomes layered sheet 172 as illustrated in FIG. 9 . As shown in FIG. 9 , the prime lanes p 1 , p 2 and p 3 have a thickness t 4 , t 5 and t 6 , respectfully. In this embodiment, thicknesses t 1 , t 2 and t 3 are in a range from about 20 mils to about 70 mils. Alternatively, the thicknesses t 1 , t 2 and t 3 could be more than 70 mils or less than 20 mils. In this embodiment, thicknesses t 4 , t 5 and t 6 are in a range from about 40 mils to about 100 mils. Alternatively, the thicknesses t 4 , t 5 and t 6 could be more than 100 mils or less than 40 mils. In this embodiment, the auxiliary coater 170 is a mechanism that sprays an additional layer 122 of asphalt material 118 onto the prime lanes p 1 , p 2 , and p 3 . Alternatively, the additional layer 122 of asphalt material 118 can be applied to the formed sheet 154 in another manner, such as by a dispenser or an extruder, or by any other manner sufficient to deposit an additional layer 122 of asphalt material 118 onto the prime lanes p 1 , p 2 , and p 3 . In one such embodiment, the additional asphalt 118 is a weathering asphalt, and the initial asphalt coating is a less weatherable asphalt, thereby further reducing the cost of the asphalt used in the shingle construction. Alternatively, the first asphalt utilizes a higher filler level and/or the additional asphalt 118 may include additional additives or comprise an adhesive material to retain the granules or provide impact resistance as described in commonly assigned U.S. Pat. No. 6,426,309, which is incorporated herein by reference in its entirety.
[0056] In yet another embodiment, apparatus 210 for manufacturing an asphalt-based roofing shingle is shown in FIG. 10 . An asphalt-coated sheet 220 , including headlap lanes h 1 , h 2 and h 3 and prime lanes, p 1 , p 2 and p 3 , is fed between a top compression roll 232 and a bottom compression roll 234 . In this embodiment, the top compression roll 232 and the bottom compression roll 234 are rotating drums as shown in FIG. 11 . Referring again to FIG. 10 , as the asphalt-coated sheet 220 feeds between the top compression roll 232 and the bottom compression roll 234 , the asphalt-coated sheet 220 is compressed and excess asphalt is squeezed from the asphalt-coated sheet 220 .
[0057] As shown in FIG. 11 , the top compression roll 232 comprises a single roll region 240 having a consistent roll diameter d 200 . Similarly, the bottom compression roll 234 has a single bottom roll region 252 having a consistent bottom roll diameter b 200 .
[0058] Referring again to FIG. 10 , in operation, as the asphalt-coated sheet 220 passes between the top compression roll 232 and the bottom compression roll 234 , the headlap lanes h 1 , h 2 and h 3 of the asphalt-coated sheet 220 , and the prime lanes p 1 , p 2 , and p 3 pass between roll region 240 of the top compression roll 232 and roll region 252 of the bottom compression roll 234 . As the headlap lanes h 1 , h 2 and h 3 and the prime lanes p 1 , p 2 , and p 3 pass between roll region 240 of the top compression roll 232 and roll region 252 of the bottom compression roll 234 , the headlap lanes h 1 , h 2 and h 3 and the prime lanes p 1 , p 2 , and p 3 are compressed to thickness t 200 . In this embodiment, the top compression roll 232 and the bottom compression roll 234 compress the asphalt-coated sheet 220 to a uniform consistent thickness t 200 .
[0059] The asphalt-coated sheet 220 exits the compression of the top compression roll 232 and the bottom compression roll 234 as a formed sheet 254 as shown in FIG. 10 . Formed sheet 254 includes headlap lanes h 1 , h 2 and h 3 and prime lanes p 1 , p 2 and p 3 , each having thicknesses t 200 . The formed sheet 254 passes under an asphalt remover 270 . In this embodiment, the asphalt remover 270 is configured to remove a layer of asphalt material from the top of the headlap lanes h 1 , h 2 , and h 3 of the formed sheet 254 . After removing a layer of asphalt material from the top of the headlap lanes h 1 , h 2 , and h 3 , the formed sheet 254 becomes layered sheet 272 as illustrated in FIG. 12 . As shown in FIG. 12 , the prime lanes p 1 , p 2 and p 3 have a thickness t 4 , t 5 and t 6 , respectfully. In this embodiment, thicknesses t 1 , t 2 and t 3 are in a range from about 20 mils to about 70 mils. Alternatively, the thicknesses t 1 , t 2 and t 3 could be more than 70 mils or less than 20 mils. In this embodiment, thicknesses t 4 , t 5 and t 6 are in a range from about 40 mils to about 100 mils. Alternatively, the thicknesses t 4 , t 5 and t 6 could be more than 100 mils or less than 40 mils.
[0060] In this embodiment as shown in FIG. 10 , the asphalt remover 270 is a scraper having one or more scraping blades. In another embodiment, the asphalt remover 270 could be any mechanism, structure or assembly, such as an abrasive wheel or a suction device, sufficient to remove a layer of asphalt material from one or more of the top and/or bottom of the headlap lanes h 1 , h 2 and h 3 . Alternatively, the outboard lanes h 1 and h 3 may be reduced in thickness, or the center lane h 2 may be of reduced thickness.
[0061] In yet another embodiment, apparatus 310 for manufacturing an asphalt-based roofing shingle is shown in FIG. 13 . A resulting asphalt-coated sheet 320 , including headlap lanes h 1 , h 2 and h 3 and prime lanes, p 1 , p 2 and p 3 , is then passed between a top compression roll 332 and a bottom compression roll 334 . In this embodiment, the top compression roll 332 and the bottom compression roll 334 are rotating drums as shown in FIG. 14 . Referring again to FIG. 13 , as the asphalt-coated sheet 320 feeds between the top compression roll 32 and the bottom compression roll 334 , the asphalt-coated sheet 320 is compressed and excess asphalt is squeezed from the asphalt-coated sheet 320 .
[0062] As shown in FIG. 14 , the top compression roll 332 comprises different roll regions having different roll diameters that correspond to the headlap and prime lanes of the asphalt-coated sheet 320 . In this embodiment, the top compression roll 332 includes roll regions 340 , 342 and 344 . Roll region 340 has a roll diameter d 301 , roll region 342 has a roll diameter d 302 and roll region 344 has a roll diameter d 303 . The top compression roll 332 also includes roll regions 346 , 348 and 350 . Roll region 346 has a roll diameter d 304 , roll region 348 has a roll diameter d 305 and roll region 350 has a roll diameter d 306 .
[0063] In this embodiment as further shown in FIG. 14 , the bottom compression roll 334 has a bottom roll region 352 . The bottom roll region 352 has a bottom roll diameter b 301 .
[0064] In operation, as the asphalt-coated sheet 320 passes between the top compression roll 332 and the bottom compression roll 334 , headlap lanes h 1 of the asphalt-coated sheet 320 passes between roll region 340 of the top compression roll 332 and roll region 352 of the bottom compression roll 334 . As the headlap lane h 1 passes between roll region 340 of the top compression roll 332 and roll region 352 of the bottom compression roll 334 , the headlap lane h 1 is compressed to thickness t 301 . In a similar manner, as headlap lanes h 2 and h 3 pass between roll regions 342 and 344 of the top compression roll 332 and roll region 352 of the bottom compression roll 334 , headlap lanes h 2 and h 3 are compressed to thicknesses t 302 and t 303 . Also in a similar manner, as prime lanes p 1 , p 2 and p 3 pass between roll regions 346 , 348 and 350 of the top compression roll 332 and roll region 352 of the bottom compression roll 334 , prime lanes p 1 , p 2 and p 3 are compressed to thicknesses t 304 , t 305 and t 306 . In this embodiment as shown in FIG. 14 , the d 301 , d 302 and d 303 diameters of roll regions 340 , 342 and 344 , corresponding to headlap lanes h 1 , h 2 and h 3 , are the same. In another embodiment, the d 301 , d 302 and d 303 diameters of roll regions 340 , 342 and 344 could be different. Similarly, in this embodiment as shown in FIG. 14 , the d 304 , d 305 and d 306 diameters of roll regions 346 , 348 and 350 , corresponding to prime lanes p 1 , p 2 and p 3 , are the same. In another embodiment, the d 304 , d 305 and d 306 diameters of roll regions 346 , 348 and 350 could be different.
[0065] The asphalt-coated sheet 320 exits the compression of the top compression roll 332 and the bottom compression roll 334 as a formed sheet 354 as shown in FIG. 15 . Formed sheet 354 includes headlap lanes h 1 , h 2 and h 3 having thicknesses t 301 , t 302 and t 303 . Formed sheet 354 also includes prime lanes p 1 , p 2 and p 3 having thicknesses t 304 , t 305 and t 306 . In this embodiment, thicknesses t 301 , t 302 and t 303 are in a range from about 20 mils to about 70 mils. Alternatively, the thicknesses t 301 , t 302 and t 303 could be more than 70 mils or less than 20 mils. In this embodiment, thicknesses t 304 , t 305 and t 306 are in a range from about 40 mils to about 100 mils. Alternatively, the thicknesses t 304 , t 305 and t 306 could be more than 100 mils or less than 40 mils.
[0066] Referring again to FIG. 13 , formed sheet 354 is then passed underneath a film application unit 380 . The film application unit 380 is configured to apply a film 382 to the headlap lanes h 1 , h 2 , and h 3 . The film 382 is configured to strengthen the headlap lanes h 1 , h 2 and h 3 . By applying the film 382 to the headlap lanes h 1 , h 2 and h 3 , the step of applying granules to the headlap lanes h 1 , h 2 and h 3 can be eliminated, thereby resulting in a more lightweight shingle. More lightweight shingles can result in reduced transportation costs and reduced labor costs. As shown in FIG. 13 , the film 382 is made of a vinyl or PVC film. Alternatively, the film 382 can be another material, such as polyester, PVA polypropylene, metallic foil, fabric or any other material sufficient to strengthen the headlap lanes h 1 , h 2 , and h 3 . The film 382 can be made of fibers or reinforced with fibers. The film 382 can comprise a material that is tacky for the granules, or the film 382 can be a material to which the granules do not readily adhere.
[0067] After passing underneath the film application unit 380 , the formed sheet 354 becomes a filmed sheet 384 . The filmed sheet 384 passes beneath a granule hopper 356 for dispensing granules to the prime lanes p 1 , p 2 and p 3 . Although a single granule blender 356 is shown in the embodiment illustrated in FIG. 13 , any suitable number and configuration of granule blenders, including an applicator for background granules, can be used.
[0068] As shown in FIG. 13 , after the granules are deposited on the prime lanes p 1 , p 2 , and p 3 of the laminated sheet 384 , the granule-covered sheet 362 is turned around a slate drum 364 to press the granules into the asphalt coating and to temporarily invert the granule-covered sheet 362 so that the excess granules fall off. The excess granules are recovered and reused. The granule-covered sheet 362 is subsequently fed through a cutter 374 that cuts the granule-covered sheet 362 into individual shingles.
[0069] The principle and mode of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope. | A method of manufacturing roofing shingles comprises the steps of: coating a continuously supplied shingle mat with roofing asphalt to make an asphalt-coated sheet, the asphalt-coated sheet having at least one prime portion and at least one headlap portion, varying the thickness of the asphalt-coated sheet such that the at least one prime portion of the asphalt-coated sheet has a first thickness and the headlap portion has a second thickness, the thickness of the asphalt-coated sheet being varied by passing the asphalt-coated sheet through compression rollers, applying granules onto the asphalt-coated sheet to form a granule-covered sheet, and cutting the granule-covered sheet into shingles. | 4 |
[0001] The instant invention relates to liquid compositions comprising derivatives of diaminostilbene, binders and divalent metal salts for the optical brightening of substrates suitable for high quality ink jet printing.
BACKGROUND OF THE INVENTION
[0002] Ink jet printing has in recent years become a very important means for recording data and images onto a paper sheet. Low costs, easy production of multicolour images and relatively high speed are some of the advantages of this technology. Ink jet printing does however place great demands on the substrate in order to meet the requirements of short drying time, high print density and sharpness, and reduced colour-to-colour bleed. Furthermore, the substrate should have a high brightness. Plain papers for example are poor at absorbing the water-based anionic dyes or pigments used in ink jet printing; the ink remains for a considerable time on the surface of the paper which allows diffusion of the ink to take place and leads to low print sharpness. One method of achieving a short drying time while providing high print density and sharpness is to use special silica-coated papers. Such papers however are expensive to produce.
[0003] U.S. Pat. No. 6,207,258 provides a partial solution to this problem by disclosing that pigmented ink jet print quality can be improved by treating the substrate surface with an aqueous sizing medium containing a divalent metal salt. Calcium chloride and magnesium chloride are preferred divalent metal salts. The sizing medium may also contain other conventional paper additives used in treating uncoated paper. Included in conventional paper additives are optical brightening agents (OBAs) which are well known to improve considerably the whiteness of paper and thereby the contrast between the ink jet print and the background. U.S. Pat. No. 6,207,258 offers no examples of the use of optical brightening agents with the invention.
[0004] WO 2007/044228 claims compositions including an alkenyl succinic anhydride sizing agent and/or an alkyl ketene dimmer sizing agent, and incorporating a metallic salt. No reference is made to the use of optical brightening agents with the invention.
[0005] WO 2008/048265 claims a recording sheet for printing comprising a substrate formed from ligno cellulosic fibres of which at least one surface is treated with a water soluble divalent metal salt. The recording sheet exhibits an enhanced image drying time. Optical brighteners are included in a list of optional components of a preferred surface treatment comprising calcium chloride and one or more starches. No examples are provided of the use of optical brighteners with the invention.
[0006] WO 2007/053681 describes a sizing composition that, when applied to an ink jet substrate, improves print density, colour-to-colour bleed, print sharpness and/or image dry time. The sizing composition comprises at least one pigment, preferably either precipitated or ground calcium carbonate, at least one binder, one example of which is a multicomponent system including starch and polyvinyl alcohol, at least one nitrogen containing organic species, preferably a polymer or copolymer of diallyldimethyl ammonium chloride (DADMAC), and at least one inorganic salt. The sizing composition may also contain at least one optical brightening agent, examples of which are Leucophor BCW and Leucophor FTS from Clariant.
[0007] The advantages of using a divalent metal salt, such as calcium chloride, in substrates intended for pigmented ink jet printing can only be fully realized when a compatible water-soluble optical brightener becomes available. It is well-known however that water-soluble optical brighteners are prone to precipitation in high calcium concentrations. (See, for example, page 50 in Tracing Technique in Geohydrology by Werner Käss and Horst Behrens, published by Taylor & Francis, 1998.)
[0008] Accordingly, there is a need for a water-soluble optical brightener which has good compatibility with sizing compositions containing a divalent metal salt.
DESCRIPTION OF THE INVENTION
[0009] It has now been found that optical brighteners of formula (1) have surprisingly good compatibility with sizing compositions containing a divalent metal salt.
[0010] The present invention therefore provides a sizing composition for optical brightening of substrates, preferably paper, which is especially suitable for pigmented ink jet printing, comprising
(a) at least one binder; (b) at least one divalent metal salt, the at least one divalent metal salt being selected from the group consisting of calcium chloride, magnesium chloride, calcium bromide, magnesium bromide, calcium iodide, magnesium iodide, calcium nitrate, magnesium nitrate, calcium formate, magnesium formate, calcium acetate, magnesium acetate, calcium sulphate, magnesium sulphate, calcium thiosulphate or magnesium thiosulphate or mixtures of said compounds; (c) water, and (d) at least one optical brightener of formula (1)
[0000]
[0000] in which
M and X are identical or different and independently from each other selected from the group consisting of hydrogen, an alkali metal cation, ammonium, ammonium which is mono-, di- or trisubstituted by a C1-C4 linear or branched alkyl radical, ammonium which is mono-, di- or trisubstituted by a C 1 -C 4 linear or branched hydroxyalkyl radical, or mixtures of said compounds and n is in the range from 0 to 6.
[0017] Preferred compounds of formula (1) are those in which
M and X are identical or different and independently from each other selected from the group consisting of an alkali metal cation and trisubstituted C1-C4 linear or branched hydroxyalkyl radical, or mixtures of said compounds and n is in the range from 0 to 6.
[0020] More preferred compounds of formula (1) are those in which
M and X are identical or different and independently from each other selected from the group consisting of Li, Na, K and trisubstituted C1-C3 linear or branched hydroxyalkyl radical, or mixtures of said compounds and n is in the range from 0 to 6.
[0023] Especially preferred compounds of formula (1) are those in which
M and X are identical or different and independently from each other selected from the group consisting of Na, K and triethanolamine, or mixtures of said compounds and n is in the range from 0 to 6.
[0026] The concentration of optical brightener in the sizing composition may be between 0.2 and 30 g/l, preferably between 1 and 15 g/l, most preferably between 2 and 12 g/l.
[0027] The binder is typically an enzymatically or chemically modified starch, e.g. oxidized starch, hydroxyethylated starch or acetylated starch. The starch may also be native starch, anionic starch, a cationic starch, or an amphipathic depending on the particular embodiment being practiced. While the starch source may be any, examples of starch sources include corn, wheat, potato, rice, tapioca, and sago. One or more secondary binders e.g. polyvinyl alcohol may also be used.
[0028] The concentration of binder in the sizing composition may be between 1 and 30% by weight, preferably between 2 and 20% by weight, most preferably between 5 and 15% by weight.
[0029] Preferred divalent metal salts are selected from the group consisting of calcium chloride, magnesium chloride, calcium bromide, magnesium bromide, calcium sulphate, magnesium sulphate, calcium thiosulphate or magnesium thiosulphate or mixtures of said compounds.
[0030] Even more preferred divalent metal salts are selected from the group consisting of calcium chloride or magnesium chloride or mixtures of said compounds.
[0031] The concentration of divalent metal salt in the sizing composition may be between 1 and 100 g/l, preferably between 2 and 75 g/l, most preferably between 5 and 50 g/l.
[0032] When the divalent metal salt is a mixture of a calcium salt and a magnesium salt, the amount of calcium salt may be in the range of 0.1 to 99.9%.
[0033] The pH value of the sizing composition is typically in the range of 5-13, preferably 6-11.
[0034] In addition to one or more binders, one or more divalent metal salts, one or more optical brighteners and water, the sizing composition may contain by-products formed during the preparation of the optical brightener as well as other conventional paper additives. Examples of such additives are carriers, defoamers, wax emulsions, dyes, inorganic salts, solubilizing aids, preservatives, complexing agents, surface sizing agents, cross-linkers, pigments, special resins etc.
[0035] In an additional aspect of the invention, the optical brightener may be pre-mixed with polyvinyl alcohol in order to boost the performance of the optical brightener in sizing compositions. The polyvinyl alcohol may have any hydrolysis level including from 60 to 99%. The optical brightener/polyvinyl alcohol mixture may contain any amount of optical brightener and polyvinyl alcohol. Examples of making optical brightener/polyvinyl alcohol mixtures can be found in WO 2008/017623.
[0036] The optical brightener/polyvinyl alcohol mixture may be an aqueous mixture.
[0037] The optical brightener/polyvinyl alcohol mixture may contain any amount of optical brightener including from 10 to 50% by weight of at least one optical brightener. Further, the optical brightener/polyvinyl alcohol mixture may contain any amount of polyvinyl alcohol including from 0.1 to 10% by weight of polyvinyl alcohol.
[0038] The sizing composition may be applied to the surface of a paper substrate by any surface treatment method known in the art. Examples of application methods include size-press applications, calendar size application, tub sizing, coating applications and spraying applications. (See, for example, pages 283-286 in Handbook for Pulp & Paper Technologists by G. A. Smook, 2 nd Edition Angus Wilde Publications, 1992 and US 2007/0277950.) The preferred method of application is at the size-press such as puddle size press or rod-metered size press. A preformed sheet of paper is passed through a two-roll nip which is flooded with the sizing composition. The paper absorbs some of the composition, the remainder being removed in the nip.
[0039] The paper substrate contains a web of cellulose fibres which may be synthetic or sourced from any fibrous plant including woody and nonwoody sources. Preferably the cellulose fibres are sourced from hardwood and/or softwood. The fibres may be either virgin fibres or recycled fibres, or any combination of virgin and recycled fibres.
[0040] The cellulose fibres contained in the paper substrate may be modified by physical and/or chemical methods as described, for example, in Chapters 13 and 15 respectively in Handbook for Pulp & Paper Technologists by G. A. Smook, 2 nd Edition Angus Wilde Publications, 1992. One example of a chemical modification of the cellulose fibre is the addition of an optical brightener as described, for example, in EP 884,312, EP 899,373, WO 02/055646, WO 2006/061399, WO 2007/017336, WO 2007/143182, US 2006-0185808, and US 2007-0193707.
[0041] The sizing composition is prepared by adding the optical brightener (or optical brightener/polyvinyl alcohol mixture) and the divalent metal salt to a preformed aqueous solution of the binder at a temperature of between 20° C. and 90° C. Preferably the divalent metal salt is added before the optical brightener (or optical brightener/polyvinyl alcohol mixture), and at a temperature of between 50° C. and 70° C.
[0042] The paper substrate containing the sizing composition and of the present invention may have any ISO brightness, including ISO brightness that is at least 80, at least 90 and at least 95.
[0043] The paper substrate of the present invention may have any CIE Whiteness, including at least 130, at least 146, at least 150, and at least 156. The sizing composition has a tendency to enhance the CIE Whiteness of a sheet as compared to conventional sizing compositions containing similar levels of optical brighteners.
[0044] The sizing composition of the present invention has a decreased tendency to green a sheet to which it has been applied as compared to that of conventional sizing compositions containing comparable amounts of optical brighteners. Greening is a phenomenon related to saturation of the sheet such that a sheet does not increase in whiteness even as the amount of optical brightener is increased. The tendency to green is measured is indicated by from the a*-b* diagram, a* and b* being the colour coordinates in the CIE Lab system. Accordingly, the sizing composition of the present invention affords the user the ability to efficiently increase optical brightener concentrations on the paper in the presence of a divalent metal ion without reaching saturation, while at the same time maintaining or enhancing the CIE Whiteness and ISO Brightness of the paper.
[0045] While the paper substrates of the present invention show enhanced properties suitable for inkjet printing, the substrates may also be used for multi-purpose and laserjet printing as well. These applications may include those requiring cut-size paper substrates, as well as paper roll substrates.
[0046] The paper substrate of the present invention may contain an image. The image may be formed on the substrate with any substance including dye, pigment and toner.
[0047] Once the image is formed on the substrate, the print density may be any optical print density including an optical print density that is at least 1.0, at least 1.2, at least 1.4, at least 1.6. Methods of measuring optical print density can be found in EP 1775141.
[0048] The preparation of a compound of formula (1) in which M=Na and n=6 has been described previously in WO 02/060883 and WO 02/077106. No examples have been provided of the preparation of a compound of formula (1) in which M≠X and n<6.
[0049] The compounds of formula (1) are prepared by stepwise reaction of a cyanuric halide with
[0050] a) an amine of formula
[0000]
[0000] in the free acid, partial- or full salt form,
[0051] (b) a diamine of formula
[0000]
in the free acid, partial- or full salt form,
and
[0053] c) diisopropanolamine of formula
[0000]
[0054] As a cyanuric halide there may be employed the fluoride, chloride or bromide. Cyanuric chloride is preferred.
[0055] Each reaction may be carried out in an aqueous medium, the cyanuric halide being suspended in water, or in an aqueous/organic medium, the cyanuric halide being dissolved in a solvent such as acetone. Each amine may be introduced without dilution, or in the form of an aqueous solution or suspension. The amines can be reacted in any order, although it is preferred to react the aromatic amines first. Each amine may be reacted stoichiometrically, or in excess. Typically, the aromatic amines are reacted stoichimetrically, or in slight excess; diisopropanolamine is generally employed in an excess of 5-30% over stoichiometry.
[0056] For substitution of the first halogen of the cyanuric halide, it is preferred to operate at a temperature in the range of 0 to 20° C., and under acidic to neutral pH conditions, preferably in the pH range of 2 to 7. For substitution of the second halogen of the cyanuric halide, it is preferred to operate at a temperature in the range of 20 to 60° C., and under weakly acidic to weakly alkaline conditions, preferably at a pH in the range of 4 to 8. For substitution of the third halogen of the cyanuric halide, it is preferred to operate at a temperature in the range of 60 to 102° C., and under weakly acidic to alkaline conditions, preferably at a pH in the range of 7 to 10.
[0057] The pH of each reaction is generally controlled by addition of a suitable base, the choice of base being dictated by the desired product composition. Preferred bases are, for example, alkali metal (e.g., lithium, sodium or potassium) hydroxides, carbonates or bicarbonates, or aliphatic tertiary amines e.g. triethanolamine or triisopropanolamine. Where a combination of two or more different bases is used, the bases may be added in any order, or at the same time.
[0058] Where it is necessary to adjust the reaction pH using acid, examples of acids that may be used include hydrochloric acid, sulphuric acid, formic acid and acetic acid.
[0059] Aqueous solutions containing one or more compounds of general formula (1) may optionally be desalinated either by membrane filtration or by a sequence of precipitation followed by solution using an appropriate base.
[0060] The preferred membrane filtration process is that of ultrafiltration using, e.g., polysulphone, polyvinylidenefluoride, cellulose acetate or thin-film membranes.
EXAMPLES
[0061] The following examples shall demonstrate the instant invention in more details. If not indicated otherwise, “parts” means “parts by weight” and “%” means “% by weight”.
Example 1
[0062] Stage 1: 31.4 parts of aniline-2,5-disulphonic acid monosodium salt are added to 150 parts of water and dissolved with the aid of an approx. 30% sodium hydroxide solution at approx. 25° C. and a pH value of approx. 8-9. The obtained solution is added over a period of approx. 30 minutes to 18.8 parts of cyanuric chloride dispersed in 30 parts of water, 70 parts of ice and 0.1 part of an antifoaming agent. The temperature is kept below 5° C. using an ice/water bath and if necessary by adding ice into the reaction mixture. The pH is maintained at approx. 4-5 using an approx. 20% sodium carbonate solution. At the end of the addition, the pH is increased to approx. 6 using an approx. 20% sodium carbonate solution and stirring is continued at approx. 0-5° C. until completion of the reaction (3-4 hours).
[0063] Stage 2: 8.8 parts of sodium bicarbonate are added to the reaction mixture. An aqueous solution, obtained by dissolving under nitrogen 18.5 parts of 4,4′-diaminostilbene-2,2′-disulphonic acid in 80 parts of water with the aid of an approx. 30% sodium hydroxide solution at approx. 45-50° C. and a pH value of approx. 8-9, is dropped into the reaction mixture. The resulting mixture is heated at approx. 45-50° C. until completion of the reaction (3-4 hours).
[0064] Stage 3: 17.7 parts of Diisopropanolamine are then added and the temperature is gradually raised to approx. 85-90° C. and maintained at this temperature until completion of the reaction (2-3 hours) while keeping the pH at approx. 8-9 using an approx. 30% sodium hydroxide solution. The temperature is then decreased to 50° C. and the reaction mixture is filtered and cooled down to room temperature. The solution is adjusted to strength to give an aqueous solution of a compound of formula (1) in which M=X=Na and n=6 (0.125 mol/kg, 17.8%).
Example 2
[0065] An aqueous solution of a compound of formula (1) in which M=Na, X=K and 4.5≦n≦5.5 (0.125 mol/kg, approx. 18.0%) is obtained following the same procedure as in Example 1 with the sole difference that an approx. 30% potassium hydroxide solution is used instead of an approx. 30% sodium hydroxide solution in Stage 3.
Example 3
[0066] An aqueous solution of a compound of formula (1) in which M=Na, X=K and 2.5≦n≦4.5 (0.125 mol/kg, approx. 18.3%) is obtained following the same procedure as in Example 1 with the sole differences that 10 parts of potassium bicarbonate are used instead of 8.8 parts of sodium bicarbonate in Stage 2 and an approx. 30% potassium hydroxide solution is used instead of an approx. 30% sodium hydroxide solution in Stages 2 and 3.
Example 4
[0067] An aqueous solution of a compound of formula (1) in which M=Na, X=K and 0≦n≦2.5 (0.125 mol/kg, approx. 18.8%) is obtained following the same procedure as in Example 1 with the sole differences that an approx. 30% potassium hydroxide solution is used in place of an approx. 30% sodium hydroxide solution in Stages 1, 2 and 3, an approx. 20% potassium carbonate solution is used instead of an approx. 20% sodium carbonate solution in Stage 1, and 10 parts of potassium bicarbonate are used instead of 8.8 parts of sodium bicarbonate in Stage 2.
Example 5
[0068] An aqueous solution of a compound of formula (1) in which M=Na, X=Li and 4.5≦n≦5.9 (0.125 mol/kg, approx. 17.7%) is obtained following the same procedure as in Example 1 with the sole difference that an approx. 10% lithium hydroxide solution is used instead of an approx. 30% sodium hydroxide solution in Stage 3.
Example 6
[0069] An aqueous solution of a compound of formula (1) in which M=Na, X=Li and 2.5≦n≦4.5 (0.125 mol/kg, approx. 17.3%) is obtained following the same procedure as in Example 1 with the sole differences that 3.7 parts of lithium carbonate are used instead of 8.8 parts of sodium bicarbonate in Stage 2 and an approx. 10% lithium hydroxide solution is used instead of an approx. 30% sodium hydroxide solution in Stages 2 and 3.
Example 7
[0070] A compound of formula (1) in which M=H is isolated by precipitation with concentrated hydrochloric acid of the concentrated solution of the compound of formula (1) obtained in Example 1, followed by filtration. The presscake is then dissolved in an aqueous solution of 7 equivalents of triethanolamine to give an aqueous solution of a compound of formula (1) in which M=Na, X=triethanolammonium and 1≦n≦3 (0.125 mol/kg, approx. 24.2%).
Example 8
[0071] Optical brightening solution 8 is produced by stirring together
an aqueous solution containing compound of formula (1) in which M=Na, X=K and 0≦n≦2.5 prepared according to example 4, a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s and water
while heating to 90-95° C., until a clear solution is obtained that remains stable after cooling to room temperature.
[0075] The parts of each component are selected in order to get a final aqueous solution 8 comprising a compound of formula (1) in which M=Na, X=K and 0≦n≦2.5 prepared according to example 4 at a concentration of 0.125 mol/kg and 2.5% of a polyvinyl alcohol having a degree of hydrolysis of 85% and a Brookfield viscosity of 3.4-4.0 mPa·s. The pH of solution 8 is in the range 8-9.
Application Examples 1 to 8
[0076] Sizing compositions are prepared by adding an aqueous solution of a compound of formula (1) prepared according to Examples 1 to 8 at a range of concentrations from 0 to 50 g/l (from 0 to approx. 12.5 g/l of optical brightener) to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
[0077] The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 1.
Comparative Example 1
[0078] Sizing compositions are prepared by adding an aqueous solution of the Hexasulfo-compound disclosed in the table on page 8 of the US 2005/0124755 A 1 at a range of concentrations from 0 to 50 g/l (from 0 to approx. 12.5 g/l of optical brightener) to a stirred, aqueous solution of calcium chloride (35 g/l) and an anionic starch (50 g/l) (Penford Starch 260) at 60° C. The sizing solution is allowed to cool, then poured between the moving rollers of a laboratory size-press and applied to a commercial 75 g/m 2 AKD (alkyl ketene dimer) sized, bleached paper base sheet. The treated paper is dried for 5 minutes at 70° C. in a flat bed drier.
[0079] The dried paper is allowed to condition, and then measured for CIE whiteness on a calibrated Auto Elrepho spectrophotometer. The results are shown in Table 1.
[0000]
TABLE 1
CIE Whiteness
Comparative
Conc.
Application example
example
g/l
1
2
3
4
5
6
7
8
1
0
103.7
103.7
103.7
103.7
103.7
103.7
103.7
103.7
103.7
20
130.3
131.4
131.7
131.9
131.4
131.7
132.0
132.2
129.0
30
134.7
135.0
135.4
135.8
134.7
135.1
135.9
136.5
132.5
40
137.3
137.8
138.0
138.3
137.1
137.2
138.5
139.8
134.6
50
140.3
140.7
141.2
141.7
139.8
140.4
142.0
143.0
138.0
[0080] The results in Table 1 clearly demonstrate the excellent whitening effect afforded by the compositions of the invention.
[0081] Printability evaluation was done with a black pigment ink applied to the paper using a draw down rod and allowed to dry.
[0082] Optical density was measured using an Ihara Optical Densitometer R710. The results are shown in Table 2.
[0000]
TABLE 2
Optical Density
Paper sheet treated
2
1.02
according to application
4
1.12
example
7
1.06
Paper sheet treated
1
1.02
according to comparative
example
Optical Density = log 10 1/R
Where R = Reflectance
[0083] The results in Table 2 show that the composition of the invention has no adverse effect on ink print density. | The instant invention relates to liquid compositions comprising derivatives of diaminostilbene, binders and ink fixing agents such as divalent metal salts for the optical brightening of substrates suitable for high quality ink jet printing. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. patent application Ser. No. 14/525,411, filed Oct. 28, 2014, published on Oct. 1, 2015, as U.S. Publication No. 2015-0278013, now U.S. Pat. No. 9,196,385, issued on Nov. 24, 2015, entitled “LIFETIME MIXED LEVEL NON-VOLATILE MEMORY SYSTEM” (Atty. Dkt. No. GRTD-32620). Application Ser. No. 14/525,411 is a Division of U.S. patent application Ser. No. 13/455,267, filed Apr. 25, 2012, published on Jan. 24, 2013, as U.S. Publication No. 2013-0021846, now U.S. Pat. No. 8,891,298, issued on Nov. 18, 2014, entitled “LIFETIME MIXED LEVEL NON-VOLATILE MEMORY SYSTEM” (Atty. Dkt. No. GRTD-32619). Application Ser. No. 13/455,267 claims benefit of U.S. Provisional Application No. 61/509,257, filed Jul. 19, 2011, entitled “LIFETIME MIXED LEVEL NAND FLASH SYSTEM” (Atty. Dkt. No. GRTD-32624). U.S. Pat. Nos. 9,196,385 and 8,891,298 and Patent Application Publication Nos. 2015-0278013 and 2013-0021846 are hereby incorporated by reference in their entirety. This application also incorporates by reference the complete disclosure of U.S. patent application Ser. No. 12/256,362, filed Oct. 22, 2008, published on Apr. 30, 2009, as U.S. Publication No. 2009-0109787, now U.S. Pat. No. 7,855,916, issued on Dec. 21, 2010, entitled “NONVOLATILE MEMORY SYSTEMS WITH EMBEDDED FAST READ AND WRITE MEMORIES” (Atty. Dkt. No. GRTD-32614). This application also incorporates by reference the complete disclosure of U.S. patent application Ser. No. 12/915,177, filed Oct. 29, 2010, published on Mar. 10, 2011, as U.S. Publication No. 2011-0060870, now U.S. Pat. No. 8,194,452, issued on Jun. 5, 2012, entitled “NONVOLATILE MEMORY SYSTEMS WITH EMBEDDED FAST READ AND WRITE MEMORIES” (Atty. Dkt. No. 32615).
TECHNICAL FIELD
[0002] This application relates to a system and method for providing reliable storage through the use of non-volatile memories and, more particularly, to a system and method of increasing the reliability and lifetime of a NAND flash storage system, module, or chip through the use of a combination of single-level cell (SLC) and multi-level cell (MLC) NAND flash storage without substantially raising the cost of the NAND flash storage system. The memory in a total non-volatile memory system may contain some SRAM (static random-access memory), DRAM (dynamic RAM), RRAM (resistive RAM), PCM (phase change memory), MAGRAM (magnetic random-access memory), NAND flash, and one or more HDDs (hard disk drives) when storage of the order of several terabytes is required. The SLC non-volatile memory can be flash, PCM, RRAM, MAGRAM or any other solid-state non-volatile memory as long as it has endurance that is superior to that of MLC flash, and it provides for data access speeds that are faster than that of MLC flash or rotating storage media (e.g., HDDs).
BACKGROUND
[0003] Non-volatile memories provide long-term storage of data. More particularly, non-volatile memories can retain the stored data even when not powered. Magnetic (rotating) hard disk drives (HDD) dominate this storage medium due to lower cost compared to solid state disks (SSD). Optical (rotating) disks, tape drives and others have a smaller role in long-term storage systems. SSDs are preferred for their superior performance (fast access time), mechanical reliability and ruggedness, and portability. Flash memory, more specifically NAND flash, is the dominant SSD medium today.
[0004] RRAM, PCM, MAGRAM and others, will likely play a larger role in the future, each of them having their own advantages and disadvantages. They may ultimately replace flash memories, initially for use as a “write buffer” and later to replace “SLC flash” and “MLC flash.” MLC NAND flash is a flash memory technology using multiple levels per cell to allow more bits to be stored using the same number of transistors. In SLC NAND flash technology, each cell can exist in one of two states, storing one bit of information per cell. Most MLC NAND flash memory has four possible states per cell, so it can store two bits of information per cell.
[0005] These semiconductor technology driven “flash alternatives,” i.e., RRAM, PCM, MAGRAM and others, have several advantages over any (SLC or MLC) flash because they: 1) allow data to be written over existing data (without prior erase of existing data), 2) allow for an erase of individual bytes or pages (instead of having to erase an entire block), and 3) possess superior endurance (1,000,000 write-erase cycles compared to typical 100,000 cycles for SLC flash and less than 10,000 cycles for MLC flash).
[0006] HDDs have several platters. Each platter contains 250-5,000 tracks (concentric circles). Each track contains 64 to 256 sectors. Each sector contains 512 bytes of data and has a unique “physical (memory) address.” A plurality of sectors is typically combined to form a “logical block” having a unique “logical address.” This logical address is the address at which the logical block of physical sectors appears to reside from the perspective of an executing application program. The size of each logical block and its logical address (and/or address ranges/boundaries) is optimized for the particular operating system (OS) and software applications executed by the host processor. A computer OS organizes data as “files.” Each file may be located (stored) in either a single logical block or a plurality of logical blocks, and therefore, the location of files typically traverses the boundaries of individual (physical) sectors. Sometimes, a plurality of files has to be combined and/or modified, which poses an enormous challenge for the memory controller device of a non-volatile memory system.
[0007] SSDs are slowly encroaching on the HDD space and the vast majority of NAND flash in enterprise servers utilizes a SLC architecture, which further comprises a NAND flash controller and a flash translation layer (FTL). NAND flash devices are generally fragmented into a number of identically sized blocks, each of which is further segmented into some number of pages. It should be noted that asymmetrical block sizes, as well as page sizes, are also acceptable within a device or a module containing devices. For example, a block may comprise 32 to 64 pages, each of which incorporates 2-4 Kbit of memory. In addition, the process of writing data to a NAND flash memory device is complicated by the fact that, during normal operation of, for example, single-level storage (SLC), erased bits (usually all bits in a block with the value of ‘1’) can only be changed to the opposite state (usually ‘0’) once before the entire block must be erased. Blocks can only be erased in their entirety, and, when erased, are usually written to ‘1’ bits. However, if an erased block is already there, and if the addresses (block, page, etc.) are allowed, data can be written immediately; if not, a block has to be erased before it can be written to.
[0008] FTL is the driver that works in conjunction with an existing operating system (or, in some embedded applications, as the operating system) to make linear flash memory appear to the system like a disk drive, i.e., it emulates a HDD. This is achieved by creating “virtual” small blocks of data, or sectors, out of flash's large erase blocks and managing data on the flash so that it appears to be “write in place” when in fact it is being stored in different locations in the flash. FTL further manages the flash so that there are clean/erased places to store data.
[0009] Given the limited number of writes that individual blocks within flash devices can tolerate, wear leveling algorithms are used within the flash devices (as firmware commonly known as FTL or managed by a controller) to attempt to ensure that “hot” blocks, i.e., blocks that are frequently written, are not rendered unusable much faster than other blocks. This task is usually performed within a flash translation layer. In most cases, the controller maintains a lookup table to translate the memory array physical block address (PBA) to the logical block address (LBA) used by the host system. The controller's wear-leveling algorithm determines which physical block to use each time data is programmed, eliminating the relevance of the physical location of data and enabling data to be stored anywhere within the memory array and thus prolonging the service life of the flash memory. Depending on the wear-leveling method used, the controller typically either writes to the available erased block with the lowest erase count (dynamic wear leveling); or it selects an available target block with the lowest overall erase count, erases the block if necessary, writes new data to the block, and ensures that blocks of static data are moved when their block erase count is below a certain threshold (static wear leveling).
[0010] MLC NAND flash SSDs are slowly replacing and/or coexisting with SLC NAND flash in newer SSD systems. MLC allows a single cell to store multiple bits, and accordingly, to assume more than two values; i.e., ‘0’ or ‘1’. Most MLC NAND flash architectures allow up to four (4) values per cell; i.e., ‘00’, ‘01’, ‘10’, or ‘11’. Generally, MLC NAND flash enjoys greater density than SLC NAND flash, at the cost of a decrease in access speed and lifetime (endurance). It should be noted, however, that even SLC NAND flash has a considerably lower lifetime (endurance) than rotating magnetic media (e.g., HDDs), being able to withstand only between 50,000 and 100,000 writes, and MLC NAND flash has a much lower lifetime (endurance) than SLC NAND flash, being able to withstand only between 3,000 and 10,000 writes. As is well known in the art, any “write” or “program” to a block in NAND flash (floating gate) requires an “erase” (of a block) before “write.”
[0011] Despite its limitations, there are a number of applications that lend themselves to the use of MLC flash. Generally, MLC flash is used in applications where data is read many times (but written few times) and physical size is an issue. For example, flash memory cards for use in digital cameras would be a good application of MLC flash, as MLC can provide higher density memory at lower cost than SLC memory.
[0012] When a non-volatile storage system combines HDD, SLC and MLC (setting aside volatile memory for buffering, caching etc) in a single (hybrid) system, new improvements and solutions are required to manage the methods of writing data optimally for improved life time (endurance) of flash memory. Accordingly, various embodiments of a NAND flash storage system that provides long lifetime (endurance) storage at low cost are described herein.
[0013] The following description is presented to enable one of ordinary skill in the art to make and use the disclosure and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiment and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present disclosure is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features described herein.
SUMMARY
[0014] According to one embodiment of the present disclosure, there is provided a system for storing data which comprises at least one MLC nonvolatile memory module (hereinafter referred to as “MLC module”) and at least one SLC non-volatile memory module (hereinafter referred to as “SLC module”), each module comprises a plurality of individually erasable blocks. The data storage system according to one embodiment of the present disclosure further comprises a controller for controlling both the at least one MLC module and the at least one SLC module. In particular, the controller maintains an address map comprising a list of individual logical address ranges each of which maps to a similar range of physical addresses within either the at least one MLC module or the at least one SLC module. After each write to (flash) memory, the controller conducts a data integrity check to ensure that the data was written correctly. When the data was not written correctly, the controller modifies the table so that the range of addresses on which the write failed is remapped to the next available range of physical addresses within the at least one SLC module. The SLC module can be (NAND) flash, PCM, RRAM, MAGRAM or any other solid-state non-volatile memory as long as it has endurance that is superior to that of MLC flash, and it provides for data access speeds that are faster than that of MLC flash or rotating storage media (e.g., HDDs).
[0015] According to another embodiment of the present disclosure, there is provided a system for storing data which comprises a controller that is further adapted to determine which of the blocks of the plurality of the blocks in the MLC and SLC non-volatile memory modules are accessed most frequently and wherein the controller segregates those blocks that receive frequent writes into the at least one SLC non-volatile memory module and those blocks that receive infrequent writes into the at least one MLC nonvolatile module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present disclosure will be more fully understood by reference to the following detailed description of one or more preferred embodiments when read in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout the views and in which:
[0017] FIG. 1 is a block diagram of a computer system incorporating one embodiment of the present disclosure;
[0018] FIGS. 2A and 2B are drawings depicting a translation table/address map in accordance with one embodiment of the present disclosure;
[0019] FIGS. 3A and 3B are a flow chart illustrating an exemplary method for use in implementing one embodiment of the present disclosure; and
[0020] FIG. 4 is a block diagram depicting one embodiment of the present disclosure for implementation within a NAND flash module.
DETAILED DESCRIPTION
[0021] The present disclosure is directed to the reliable storage of data in read and write memory, and, in particular, to the reliable storage of data in non-volatile memory, such as, for example, NAND flash. Generally, and in particular regard to NAND flash memory, two separate banks of NAND flash are maintained by a controller. One bank contains economical MLC NAND flash, while a second bank contains high endurance SLC NAND flash. The controller conducts a data integrity test after every write. If a particular address range fails a data integrity test, the address range is remapped from MLC NAND flash to SLC NAND flash. As the SLC NAND flash is used to boost the lifetime (endurance) of the storage system, it can be considerably lesser in amount than the MLC NAND flash. For example, a system may set SLC NAND flash equal to 12.5% or 25% of MLC NAND flash (total non-volatile memory storage space=MLC+SLC).
[0022] Turning to the Figures and to FIG. 1 in particular, a computer system 10 depicting one embodiment of the present disclosure is shown. A processor 12 is coupled to a device controller 14 , such as a chipset, using a data link well known in the art, such as a parallel bus or packet-based link. The device controller 14 provides interface functions to the processor 12 . In some computer systems, the device controller 14 may be an integral part of the (host) processor 12 . The device controller 14 provides a number of input/output ports 16 and 18 , such as, for example, serial ports (e.g., USB ports and Firewire ports) and network ports (e.g., Ethernet ports and 802.11 “Wi-Fi” ports). The device controller 14 may also control a bank of, for example, DRAM 20 . In addition, the device controller 14 controls access to one or more disks 24 , such as, for example, a rotating magnetic disk, or an optical disk, as well as two or more types of NAND flash memory. One type of NAND flash memory is a MLC NAND flash memory module 26 . Another type of NAND flash memory is a SLC NAND flash memory module 28 .
[0023] The device controller 14 maintains a translation table/address map which may include address translations for all devices in the computer system. Nonetheless, the discussion in the present disclosure will be limited only to NAND flash memory modules. In particular, the device controller 14 maintains a translation table that maps logical computer system addresses to physical addresses in each one of the MLC- and SLC-NAND flash memory modules 26 and 28 , respectively. As MLC flash memory is less expensive than SLC flash memory, on a cost per bit basis, the translation table will initially map all logical NAND flash addresses to the MLC NAND flash memory module 26 . The address ranges within the translation table will assume some minimum quantum, such as, for example, one block, although a smaller size, such as one page could be used, if the NAND flash has the capability of erasing the smaller size quantum.
[0024] A “read-modify-write” scheme is used to write data to the NAND flash. Data to be written to NAND flash is maintained in DRAM 20 . After each write to an address within a particular address range, the device controller 14 will—as time permits—perform a read on the address range to ensure the integrity of the written data. If a data integrity test fails, the address range is remapped from the MLC NAND flash memory module 26 to the next available address range in the SLC NAND flash memory module 28 .
[0025] FIGS. 2A and 2B illustrate one embodiment of a translation table/address map of the present disclosure. In FIG. 2A , a list of logical address ranges (R 0 -RN) is translated to physical address ranges. As illustrated, all of the logical address ranges are translated to blocks on the MLC NAND flash memory module 26 . However, through the application of a data integrity verification check (explained in more detail below) it is determined that, for example, address range R 2 corresponds to failed quanta of data stored in block 2 of the MLC NAND flash memory module 26 . FIG. 2B shows the quanta of data which failed the data integrity verification check (see FIG. 2A ) remapped to the next available range of physical addresses within the SLC NAND flash memory module 28 , in this example, SLC/block 0 .
[0026] FIGS. 3A and 3B are a flow chart illustrating a method for utilizing a NAND flash memory system incorporating one embodiment of the present disclosure. The method begins in a step 100 , when a command to write a quantum of data stored in DRAM to a particular location in NAND flash memory is received. In step 102 , the quantum of data is read from DRAM into memory within the device controller (which acts as the memory controller). In step 104 , both the logical address range and the NAND flash physical address range to which the quantum of data is to be written, is read into memory of the device controller. In step 106 , the quantum of data to be written is combined with the contents of the NAND flash memory. In step 108 , the NAND flash physical address range to be written is erased. In step 110 , the combined data is written to the appropriate NAND flash physical address range. In step 112 the NAND flash physical address range that was written in step 110 is read into device controller memory.
[0027] The flowchart continues in FIG. 3B . In step 114 the NAND flash physical address range that was read into device controller memory is compared with the retained data representing the combination of the previous contents of the physical address range and the quantum of data to be written. In step 116 , if the retained data matches the newly stored data in the NAND flash memory, the write was a success, and the method exits in step 118 . However, if the retained data does not match the newly stored data in the NAND flash memory, the method executes step 120 , which identifies the next quantum of available SLC NAND flash memory addresses. In step 122 , a check is made to determine if additional SLC NAND flash memory is available, and, if not, the NAND flash memory system is marked as failed, prompting a system alert step 124 . However, if additional SLC NAND flash memory is available, the failed NAND flash physical address range is remapped to the next available quantum of SLC NAND flash memory in step 126 . Execution then returns to step 110 , where the write is repeated.
[0028] Another application of one embodiment of the present disclosure, not depicted in any of the drawings, is to allocate “hot” blocks; i.e., those blocks that receive frequent writes, into the SLC NAND flash memory module 28 , while allocating “cold” blocks, i.e., those blocks that only receive infrequent writes, into the MLC NAND flash memory module 26 . This could be accomplished within the device controller 14 described above, which could simply maintain a count of those blocks that are accessed (written to) most frequently, and, on a periodic basis, such as, for example, every 1000 writes, or every 10,000 writes, transfer the contents of those blocks into the SLC NAND flash memory module 28 .
[0029] FIG. 4 depicts another embodiment of the present disclosure. The embodiment is entirely resident within a NAND flash module 50 . In particular, a standard NAND flash interface 52 is managed by flash translation layer (FTL) logic 54 . The flash translation layer (FTL) 54 manages two NAND flash memory banks 56 and 58 , whereby memory bank 56 comprises a plurality of MLC NAND flash memory modules 60 a and a plurality of SLC NAND flash memory modules 62 a . Memory bank 58 comprises a plurality of MLC NAND flash memory modules 60 b and a plurality of SLC NAND flash memory modules 62 b.
[0030] This embodiment of the present disclosure could function similarly to the system level embodiment discussed earlier with reference to FIGS. 1-3B , but the control functions, such as maintenance of the translation table/address map ( FIGS. 2A and 2B ), could be conducted within the flash translation layer (FTL) 54 instead of in a device controller 14 .
[0031] Embodiments of the present disclosure relate to a system and method of increasing the reliability and lifetime of a NAND flash storage system, module, or chip through the use of a combination of multi-level cell (MLC) and single-level cell (SLC) NAND flash storage. The above description is presented to enable one of ordinary skill in the art to make and use the disclosure and is provided in the context of a patent application and its requirements. While this disclosure contains descriptions with reference to certain illustrative aspects, it will be understood that these descriptions shall not be construed in a limiting sense. Rather, various changes and modifications can be made to the illustrative embodiments without departing from the true spirit, central characteristics and scope of the disclosure, including those combinations of features that are individually disclosed or claimed herein. Furthermore, it will be appreciated that any such changes and modifications will be recognized by those skilled in the art as an equivalent to one or more elements of the following claims, and shall be covered by such claims to the fullest extent permitted by law. | A controller for managing at least one MLC non-volatile memory module and at least one SLC non-volatile memory module. The flash controller is adapted to determine if a range of addresses listed by an entry and mapped to said at least one MLC non-volatile memory module fails a data integrity test. In the event of such a failure, the controller remaps said entry to an equivalent range of addresses of said at least one SLC non-volatile memory module. The flash controller is further adapted to determine which of the blocks in the MLC and SLC non-volatile memory modules are accessed most frequently and allocating those blocks that receive frequent writes to the SLC non-volatile memory module and those blocks that receive infrequent writes to the MLC non-volatile memory module. | 6 |
The present invention relates to a CRT (cathode ray tube), and more particularly to a CRT having an Einzel lens focus mask.
A conventional CRT has a color selection electrode or shadow mask, having a plurality of circular or slot-shaped apertures, positioned in spaced relationship to a cathodoluminescent screen. However, the small dimensions of the apertures allow only about 15 percent of an electron beam to pass through the apertures towards the CRT screen, thereby limiting brightness of the displayed image. Also during production of the CRT, a getter material, such as barium, is flashed by means of R.F. induction heating in order to form an inside coating that absorbs residual gases left in the CRT after a vacuum pump-down operation during fabrication.
U.S. Pat. No. 3,421,048 shows a method of achieving less beam current interception by the shadow mask and therefore a higher beam current incident upon the screen. In particular, an "Einzel lens" is used, i.e. additional mesh electrodes are disposed on either side of the shadow mask. The mesh electrodes have the ultor or screen voltage, e.g. 25 KV, applied thereto, while the mask has a lower applied voltage. This causes an electrostatic focusing action that reduces beam current interception by the shadow mask. In particular, said patent discloses that the shadow mask has a potential of 21.8 KV. It has been found by the present inventor that the shadow mask should have, at most, 2000 volts applied to it to increase the focusing effect, and therefore further reduce beam current interception. This also causes the shadow mask to be at the same or an only slightly higher voltage than the cathode of the electron gun to still further minimize current interception by the mask. Lower mask current interception reduces secondary electron emission from the mask. Since the secondary electrons are collected by the mesh, the minimization thereof reduces heating and therefore warping of the mesh. Further, the current requirement of the high voltage ultor power supply is also reduced.
However, a large voltage difference between the shadow mask and the meshes is now present. In turn, this results in voltage breakdown along the support structure for the meshes and the shadow mask due to the getter coating, which is metallic and therefore conducting.
The present invention overcomes the above problem.
SUMMARY OF THE INVENTION
A cathode ray tube comprises an evacuated envelope enclosing a cathodoluminescent screen at one end and an electron gun at an opposing end. A color selection electrode is disposed proximate the screen and has a relatively low voltage applied thereto to reduce electron beam interception. A pair of focusing meshes are disposed on a support frame on either side of the color selection electrode and have a relatively high voltage applied thereto for good focusing action. Support means are used for supporting the color selection electrode relative to the frame. The support means includes an insulating support element having an interior surface, and an inside support for mounting the color selection electrode to the interior surface. A lead-in wire is coupled to the color selection electrode and extends outside the cathode ray tube. An insulating tube is disposed around the lead-in wire and has an open end proximate the color selection electrode and a closed end abutting the envelope. The interior surfaces of the insulating tube and the insulating support element pick up only a very minimal amount of getter material when a getter is flashed, thus preventing voltage breakdown.
DESCRIPTION OF THE DRAWING
FIG. 1 is a cross-sectional side view of a CRT;
FIG. 2 is an inside view of the CRT showing support structure for a color selection electrode taken at line 2--2 of FIG. 1; and
FIG. 3 is an inside view of the CRT taken at line 3--3 of FIG. 2.
DETAILED DESCRIPTION
FIG. 1 shows a CRT 10 comprising an evacuated glass envelope 12 having a neck 14 and a faceplate panel 16 connected by a funnel 17. Within the neck 14 is an electron gun 18 that generates three electron beams 20B, 20G, and 20R for exciting blue, green, and red color emitting phosphors, respectively, of a cathodoluminescent screen 21. The landing position of the beams 20 is controlled by deflection coils 22 having currents determined by deflection circuits (not shown). Portions of the beams 20 pass through apertures in a focus mask 24 (described below) to strike a phosphor layer 26 of the screen 21 on the inside of the panel 16.
In particular, the focus mask 24 comprises course focusing meshes 38 and 40 placed on either side of a color selection electrode 28 to form an Einzel lens focus mask. The color selection electrode 28 has circular or slot-shaped apertures (not shown) of conventional size, e.g. 7 mils slot width for a conventional picture or smaller for a high-definition picture. The apertures have bevel-shaped cross-sections due to their being formed by etching from one side. Preferably the wide side of the bevel faces the gun 18 in order to allow a large percentage of electrons in the beams 20 to enter the apertures. The focusing effect of an Einzel lens concentrates the electrons towards the center of the apertures so they exit from the narrow side of the apertures and go to the layer 26. The openings of each of the meshes 38 and 40 comprise 80 percent of the area of the entire mesh, have the same period as the color selection electrode apertures, and are formed by etching. During fabrication, each mesh is pressed into a desired shape, and then is mounted onto a frame means 30 (shown in FIGS. 2 and 3) with the color selection electrode 28. The meshes 38 and 40 are spaced from the color selection electrode 281/4 to 1/2 inch (6.35 to 12.7 mm). The large openings in the meshes 38 and 40 and the large spacing from the color selection electrode 28 makes accurate alignment of the meshes 38 and 40 with the color selection electrode 28 unnecessary.
FIGS. 2 and 3 show details of a support means for supporting the focus mask 24 which includes the frame means 30. The frame means 30 includes a first frame 31 and a wire second frame 32. The first frame 31 is a rectangular metal structure having a C-shaped cross-section. The wire second frame 32 has corners 42, 44, 46, and 48 at which the color selection electrode 28 (not shown in FIGS. 2 and 3) is welded. The second frame 32 also comprises end portions 50 and 52. The first frame 31 has the meshes 38 and 40 welded thereto and includes springs 54 on three sides that engage studs 56 disposed on the inside of the faceplate panel 16. The studs 56 have an aquadag conducting layer (not shown) on their outside surface to connect to a similar coating on the funnel 17 of the CRT 10. This layer conveys a high voltage to an aluminum coating (not shown) on the back of the phosphor layer 26, as is conventional. Thus the layer 26 and the meshes 38 and 40 are electrically connected. A pair of outside supports 58, such as metal straps, are welded to the first frame 31 and respectively support insulating support elements, such as hollow cylindrical glass tubes 60, having interior surfaces 62. The tubes 60 are about 8 inches (203.2 mm) long, have an inside diameter of about 0.25 inch (6.35 mm) and lie in the plane of the color selection electrode 28. Cylindrical inside insulating glass supports 64 are respectively disposed within and at the centers of the tubes 60 and have an outside diameter equal to the inside diameter of the tubes 60. The supports 64 receive the respective centers of the end portions 50 and 52 of the second frame 32 in central axial holes thereof.
In order to apply a voltage to the color selection electrode 28, a lead-in or feed through wire 66 is attached to the bottom of the wire second frame 32. The wire 66 is bent at a right angle to form horizontal and vertical portions (as shown in FIGS. 2 and 3 taken together) and has an insulating glass tube 68 disposed around its vertical portion. The tube 68, which has a length of about 2 inches (50.8 mm) and an inside diameter of about 0.125 inch (3.175 mm) and lies in the plane of the color selection electrode 28, is closed at its bottom. The bottom of the tube 68 abuts the inside surface of the panel 16 and the funnel 17. The tube 68 has an interior surface 70. The vertical portion of the wire 66 extends out through a frit seal between the panel 16 and the funnel 17 to the outside of the CRT where a conventional connector cap (not shown) is attached.
In operation, the meshes 38 and 40 and the screen 21 have a high voltage, e.g. 25 KV, applied thereto. The color selection electrode 28 has a much lower voltage applied thereto to maximize the lens effect of the focus mask, therefore minimizing interception of electrons in the beam 20. In general, the color selection electrode 28 has a voltage at least equal to or greater than that of the G1 control electrode (not shown) of the electron gun 18 in order to prevent beam current interception. In a typical application where the cathode of the gun 18 has a voltage of +200 volts, and the G1 voltage is 0 volts, the minimum voltage for the color selection electrode 28 is therefore 0 volts. The maximum voltage for the color selection electrode 28 has been found to be about 2000 volts to reduce interception of electrons of the beams 20 by the color selection electrode 28 and therefore reduce secondary emission therefrom.
The foregoing mode of operation creates a large voltage difference between the color selection electrode 28 and the meshes 38 and 40. Such large voltage-differences have caused voltage breakdowns within the envelopes 12 of the prior art tubes because of deposits of the getter material. However, in the present invention, due to the large length to diameter ratios of the tubes 60 and 68 (about 16:1 for the numerical values given above and considering that the supports 64 divide the tubes 60 into two portions), it has been found that the getter material does not deposit on the interior surfaces 62 and 70 of the tubes 60 and 68 or on the inside insulating support 64. Therefore no spurious conduction paths exist on such surfaces or on the support 64. Thus the support and lead-in structure of the present invention does not break down when large voltage differences exist during normal display operation.
It will be appreciated that many other embodiments are possible within the spirit and scope of the invention. For example, the interior surfaces of the tubes 60 and 68 can be corregated to in order to provide a longer possible conduction path on the interior surfaces, and thus further minimize the possibility of breakdown. | A CRT has an Einzel lens focus mask with a high voltage between the shadow mask and the meshes to achieve a strong focusing action and therefore minimize beam current interception by the shadow mask. The mask is supported by an insulating block inside a tube. During gettering, the getter material does not deposit on the inside of the tube and therefore spurious conduction paths are avoided. Thus the support can withstand the high voltage. A lead-in wire for the mask has a tube surrounding it which is open near the mask. This also withstands the high voltage. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation, under 35 U.S.C. §120, of copending International Application No. PCT/EP2008/057038, filed Jun. 5, 2008, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German Patent Application DE 10 2007 032 734.1, filed Jul. 13, 2007; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to a method for regenerating at least one particle agglomerator of an exhaust-gas aftertreatment system of an internal combustion engine of a motor vehicle. The invention also relates to a motor vehicle having an internal combustion engine and an exhaust-gas aftertreatment system which is formed with at least one continuously regenerable particle agglomerator. In this respect, the invention relates in particular to the elimination of soot particles from mobile internal combustion engines, such as for example diesel engines.
[0003] It is known that the particles which are entrained in the exhaust gas flow and substantially contain carbon can be thermally burned or converted through the use of nitrogen dioxide (NO 2 ) which is also formed in the exhaust-gas aftertreatment system. For that purpose, it is known to provide particle agglomerators, for example filters, particle separators and the like, in which the entrained particles are at least temporarily trapped and accumulated. During a thermal regeneration, the particle agglomerator is heated up to such an extent (for example to above 800° C.) that a conversion of the carbon with oxygen entrained in the exhaust gas is initiated. For that purpose it is, for example, possible for burners, heating elements, electrically heatable filters or an exothermic conversion of hydrocarbons to be considered as a source for the heat energy. In contrast, the so-called continuously regenerative conversion of particles (the so-called CRT process) is based on a conversion of the carbon-containing particles at low temperatures, for example below 400° C., using nitrogen dioxide. For that purpose, it is known to conduct the exhaust gas generated by the engine through an oxidation catalytic converter, and to thereby oxidize nitrogen oxides which are already contained in the exhaust gas in order to be able to provide sufficient nitrogen dioxide for the conversion of the soot particles. The nitrogen dioxide has a high affinity to carbon, such that carbon dioxide and nitrogen are regularly formed in the event of the nitrogen dioxide coming into contact with the soot particles.
[0004] In the known method and devices, with regard to the passively regenerable particle agglomerator (CRT process), an oxidation coating is provided upstream of the particle agglomerator or directly in the particle agglomerator. However, that coating, which often contains platinum, is expensive and requires, if appropriate, additional exhaust-gas treatment devices which result in more complex exhaust-gas aftertreatment systems.
SUMMARY OF THE INVENTION
[0005] It is accordingly an object of the invention to provide a method for regenerating at least one particle agglomerator and a motor vehicle including an exhaust gas after-treatment system, which overcome the hereinafore-mentioned disadvantages and at least partially solve the highlighted problems of the heretofore-known methods and devices of this general type. In particular, the invention is intended to specify a practicable and cost-effective method for regenerating at least one particle agglomerator which particularly permits a tailored passive regeneration. In addition, the invention is also intended to specify a device which is suitable for such a method, in which the device is distinguished by a low pressure drop and a particularly high level of effectiveness in the case of small particles (for example with a mean diameter of at most 500 nanometers).
[0006] With the foregoing and other objects in view there is provided, in accordance with the invention, a method for regenerating at least one particle agglomerator of an exhaust-gas aftertreatment system of an internal combustion engine of a motor vehicle. The method comprises operating the internal combustion engine at least in one operating phase to cause a proportion of nitrogen dioxides being sufficient to ensure a conversion of carbon-containing particles in the at least one particle agglomerator to be directly generated in the exhaust gas.
[0007] This means, in particular, that the first particle agglomerator which is disposed following the internal combustion engine is regenerated in the way proposed herein. In this case, thermal regeneration is dispensed with, in such a way that the conversion from carbon-containing particles takes place at temperatures below 400° C. or even below 300° C. The particle agglomerator can fundamentally be formed in the manner of a filter, a particle separator or similar simple devices for temporarily trapping the particles. The internal combustion engine is preferably a lean-burn engine in which combustion takes place predominantly with an excess of air, such as for example in a diesel engine or a so-called lean-burn engine. In other words, it is thus proposed in this case that the internal combustion engine be operated, at least in a certain operating phase (regeneration phase) such as for example in a low-load situation, in such a way that a sufficiently high proportion of nitrogen dioxides is directly generated by the internal combustion engine. A “regeneration phase” is understood to be a time interval in which the amount of particles in the particle agglomerator is reduced, in particular by at least 20% by weight, if appropriate by at least 40% by weight or even by at least 80% by weight. The individual mechanisms of how the internal combustion engine can be correspondingly regulated are discussed in detail below. In this connection, it is thus proposed firstly that the internal combustion engine itself be used as a nitrogen oxide source for the regeneration of the particle agglomerator, in such a way that additional nitrogen oxide sources such as for example upstream oxidation catalytic converters, can be dispensed with.
[0008] In accordance with another mode of the method of the invention, the internal combustion engine places a proportion of the nitrogen dioxides (NO 2 ) in a range of from 25% by volume to 60% by volume of all of the nitrogen oxides (NO x ) present. The conditions in the combustion chamber of the internal combustion engine are thus in particular set in such a way that the proportion of the nitrogen dioxides in relation to all of the nitrogen oxides generated reaches a significant range, in particular of more than 30% by volume or even 45% by volume (these ratios can, if appropriate, likewise be considered in mol.-% for regulation). This relates specifically to the nitrogen oxide proportion during the operating phase in which the regeneration of the particle accumulator takes place. The 25% by volume can be considered in this case as a lower limit and/or as a mean value during the operating phase. It is preferably also proposed that the nitrogen dioxide proportion substantially does not exceed 60% by volume in order to still be able to generate sufficient power through the use of the internal combustion engine.
[0009] In accordance with a further mode of the method of the invention, up to the at least one particle agglomerator, solely the internal combustion engine actively generates nitrogen dioxide (NO 2 ). In other words, this means in particular that, between the internal combustion engine and the particle agglomerator in question, the exhaust-gas aftertreatment system does not have any device or measures for the targeted enrichment of the exhaust gas with nitrogen dioxide. The method and the device can therefore be of particularly simple construction, and a targeted regeneration of the particle agglomerator can be regulated through the use of corresponding operation of the internal combustion engine. Redox processes of course cannot be prevented in the exhaust gas itself, although they are often not suitable for bringing about a corresponding active, significant generation of nitrogen dioxide.
[0010] In accordance with an added mode of the invention, the method can be refined in such a way that an increase in the proportion of an exhaust-gas flow recirculated into the internal combustion engine is carried out in the operating phase. For this purpose, the exhaust-gas aftertreatment system is formed, for example, with a so-called exhaust-gas recirculation (EGR) in such a way that the exhaust gas generated by the internal combustion engine is (partially) supplied to the internal combustion engine again, in particular before the exhaust gas reaches the at least one particle agglomerator. A targeted increase in the exhaust-gas recirculation rate can lead to a significant increase in the nitrogen dioxide proportion in the exhaust gas and can thereby promote the regeneration proposed in this case. The rate of the recirculated flow is preferably in the range of up to 60% by volume, in particular in a range of from 20% by volume to 50% by volume.
[0011] In accordance with an additional mode of the method of the invention, a reduction of the combustion chamber temperature in the internal combustion engine is carried out in the operating phase. It has been found that a high nitrogen dioxide proportion is conventionally produced in the exhaust gas in combustion processes carried out at a relatively low temperature. In particular, the combustion chamber temperature is regulated for this purpose, in terms of a peak temperature of the combustion, in a range below 450° C.
[0012] In accordance with yet another mode of the method of the invention, it is also considered to be advantageous that, alternatively or in addition to the possibilities specified above, an increase in the charge pressure in the internal combustion engine is carried out in the operating phase. In this case, the exhaust-gas aftertreatment system is, for example, formed with an exhaust-gas turbocharger which results in a compression of the intake air flow. The charge pressure, that is to say the pressure in the combustion chamber of the internal combustion engine, of the fuel-air mixture, is conventionally in a range of from 30 to 50 bar. For the regeneration phase, it is now proposed, in particular, that an increase in the charge pressure by, for example, at least 15%, if appropriate even 25%, of the previously regulated charge pressure is carried out. With the increase in charge pressure, the peak temperature of the combustion in the combustion chamber and therefore the nitrogen oxide formation are also influenced.
[0013] In accordance with yet a further mode of the method of the invention, it is also possible for an increase in the oxygen content in the internal combustion engine to be carried out in the operating phase. Accordingly, the combustion is, for example, carried out with an even greater excess of air. In this way, the oxygen content in the fuel-air mixture can, for example, be increased by a value of at least 1%, and in particular in a lambda range of from 1.05 to 1.1 (approximately 1% oxygen and 2% oxygen, respectively). The so-called combustion air ratio (lambda) places the air mass m (AIR,actual) which is actually available for a combustion in relation to the minimum necessary stoichiometric air mass m (AIR,stoichiometric) which is required for a complete combustion. This effect can also, in particular temporarily, lead to the desired generation of nitrogen dioxides.
[0014] In accordance with yet an added mode of the method of the invention, for an equally effective conversion of the carbon-containing particles with a simultaneously small volume of the provided particle agglomerator, it is also proposed that the internal combustion engine be operated in such a way that carbon-containing particles, the majority of which have a mean diameter of at most 200 nanometers [nm], are generated in the exhaust gas. The internal combustion engine is very particularly preferably operated in such a way that the mean diameter is at most 100 nanometers. This fundamentally also applies in an operating state of the internal combustion engine which does not correspond to the operating phase for regenerating the particle agglomerator (regeneration phase). The very small particles can particularly favorably be converted with the provided nitrogen dioxide to form carbon monoxide and elementary nitrogen. In order to provide the particles of this size, it is necessary in particular for the outlet of the combustion chamber and the exhaust line to be adapted so as to prevent an excessive agglomeration of particles up to a size above the limit value specified herein.
[0015] In accordance with yet an additional mode of the method of the invention, it is also proposed that an active temperature increase of the exhaust gas be carried out at least in the operating phase. This means, in particular, that the exhaust gas in the exhaust-gas aftertreatment system is placed in contact with additional temperature-increasing measures, in such a way that the exhaust gas, at the latest when it comes into contact with the particles to be converted, is at a nominal temperature for significantly carrying out the CRT process. The temperature-increasing measures include in particular (uncoated) (electrically operated) heating bodies, heat exchangers and the like. The concept of the targeted or regulated (non-catalytic and/or catalytic) temperature increase of the exhaust gas in order to improve the oxidation of nitrogen monoxides in the exhaust-gas aftertreatment system can generally bring significant advantages in carrying out the CRT process, and is accordingly desirable, if appropriate, even independently of the method according to the invention described herein.
[0016] With the objects of the invention in view, there is also provided a motor vehicle, comprising an exhaust-gas aftertreatment system having at least one continuously regenerable particle agglomerator being a bypass flow filter (also referred to as a semi-filter), and an internal combustion engine being a sole active nitrogen dioxide source up to the at least one particle agglomerator.
[0017] The motor vehicle proposed herein can be operated, in particular, according to the method of the invention described herein, in such a way that a non-thermal regeneration of the at least one particle agglomerator is possible in desired operating phases. The motor vehicle proposed herein is distinguished by its particularly simply-constructed exhaust-gas aftertreatment system, with corresponding control of the internal combustion engine resulting in reliable regeneration of the particle agglomerator, in such a way that a blockage of the particle agglomerator and therefore a pressure rise across the particle agglomerator is prevented.
[0018] With regard to the configuration of the internal combustion engine as a sole (exclusive) active nitrogen oxide source, reference is made substantially to the explanations given above. With regard to the particle agglomerator proposed herein, it is specified that the latter include a bypass flow filter. A bypass flow filter of this type is distinguished in that it provides a plurality of flow paths for the exhaust gas, with the exhaust gas (theoretically) having the possibility of flowing through the particle agglomerator without coming into contact with a filter material, or flowing through the latter. For this purpose, the bypass flow filter can be constructed in the manner of a honeycomb body which is formed, for example, with channel walls which are formed at least partially from a gas-impermeable material and can optionally also include a filter medium. The gas-impermeable material (preferably a sheet metal foil) is now formed with elevations and guide blades which at least partially close off (or deflect) the channel and thereby bring about a deflection of at least a part of the exhaust gas flow towards the channel wall (or towards the filter medium). In this case, the elevations are formed in such a way that they do not completely close off the channel at any point, and thereby permit a secondary flow flowing past the elevation. One possible construction of a bypass flow filter of that type can be gathered, for example, from International Publication No. WO 01/80978 A1, corresponding to U.S. Patent Application Publication No. US 2003/0072694 A1, or from International Publication No. WO 02/00326 A1, corresponding to U.S. Pat. No. 6,712,884, in such a way that reference can be made, in particular, to those documents for explanation.
[0019] In accordance with a concomitant feature of the motor vehicle of the invention, the at least one particle agglomerator includes, in the flow direction of the exhaust gas, at least one first zone and a second zone, with the second zone extending to a downstream end side and with the second zone including an oxidation catalytic converter. This means, in particular, that the particle agglomerator can be divided into at least two zones which extend in the axial direction and over the entire cross section of the particle agglomerator, with the downstream zone, which extends to the downstream end of the particle agglomerator, being provided with an oxidation catalytic converter. In this case, the first zone is preferably catalytically inactive, that is to say, for example, free from a coating. The oxidation catalytic converter can be formed, for example, in the manner of a conventional washcoat coating with high-grade metal doping.
[0020] Other features which are considered as characteristic for the invention are set forth in the appended claims, noting that the features listed individually in the claims can be combined in any desired technologically meaningful way and highlight further embodiments of the invention.
[0021] Although the invention is illustrated and described herein as embodied in a method for regenerating at least one particle agglomerator and a motor vehicle including an exhaust gas after-treatment system, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0022] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0023] FIG. 1 is a diagrammatic, plan view of a first embodiment variant of an exhaust-gas aftertreatment system of a motor vehicle;
[0024] FIG. 2 is a graph showing a possible curve or profile of nitrogen dioxide concentration during operation of the internal combustion engine;
[0025] FIG. 3 is a fragmentary, perspective view showing details of the construction of an advantageous particle agglomerator; and
[0026] FIG. 4 is a cross-sectional view of a further embodiment of a particle agglomerator.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen a diagrammatic illustration of one possible construction of an exhaust-gas aftertreatment system 2 of an internal combustion engine 3 of a motor vehicle 4 , which construction is fundamentally suitable for carrying out the method described herein. The motor vehicle 4 therefore firstly has the internal combustion engine 3 , in particular a diesel engine, which has a plurality of combustion chambers 21 in which a supplied fuel-air mixture is burned and from which exhaust gas is discharged into the atmosphere through an exhaust line 19 .
[0028] The exhaust-gas aftertreatment system 2 shown herein has a branch for an exhaust-gas recirculation 12 , downstream of the internal combustion engine 3 in a flow direction 7 , in such a way that a part of the exhaust-gas flow can be supplied again in a regulated fashion to the combustion chambers 21 of the internal combustion engine 3 . A particle agglomerator 1 is illustrated further downstream in the flow direction 7 . The particle agglomerator 1 is followed further downstream by a turbocharger 13 , so that as exhaust gas flows through the turbocharger 13 , a turbine is simultaneously driven and the turbine compresses an air quantity which is supplied through an intake tract or part 20 to the internal combustion engine 3 .
[0029] After the exhaust gas has flowed further through the exhaust line 19 in the flow direction 7 , for example to an underbody region of the motor vehicle 4 , the exhaust gas undergoes further removal of pollutants through the use of further exhaust-gas aftertreatment units 24 . In the case illustrated herein, the exhaust gas flows in the flow direction 7 through an oxidation catalytic converter 11 , a filter 22 and an SCR catalytic converter 23 (for the selective catalytic reaction of nitrogen oxide), with the exhaust gas being mixed upstream of the SCR catalytic converter 23 with a reducing agent which is introduced through the use of a corresponding addition of reducing agent 25 . The exhaust gas which is purified and converted in this way then finally flows through the exhaust line 19 into the environment.
[0030] The construction of the exhaust-gas aftertreatment system 2 shown herein permits, in particular, a discontinuous, targeted regeneration of the particle agglomerator 1 with nitrogen dioxides, which are provided in a targeted fashion through the use of the internal combustion engine 3 .
[0031] FIG. 2 shows graphically and by way of example different curves or profiles of a nitrogen dioxide concentration of the exhaust gas generated by the internal combustion engine for a regeneration of the particle agglomerator. In this case, the abscissa 30 denotes time, while the ordinate 31 substantially illustrates the nitrogen oxide concentration.
[0032] With regard to a first curve or profile 26 , it can be seen that the nitrogen dioxide concentration is disposed mostly below a predefined regeneration field 28 during operation of the internal combustion engine 3 . If a regeneration of the particle agglomerator is now to take place, then the nitrogen dioxide concentration in the exhaust gas is adjusted through the use of a regeneration phase 29 or an operating phase of the internal combustion engine in such a way that the concentration lies in the regeneration field 28 . If the demands on the internal combustion engine change (for example power demand, load range, . . . ) or the regeneration of the particle agglomerator is to be ended, the internal combustion engine 3 can be operated with a relatively low nitrogen dioxide proportion in the exhaust gas again. It is thereby possible for a discontinuous, and at predefined and/or calculated times non-thermal, regeneration of the particle agglomerator to be carried out.
[0033] Furthermore, it is also possible for the nitrogen dioxide proportion in the exhaust gas to fundamentally be regulated in such a way that the proportion lies in the region of the regeneration field 28 at regular intervals and/or permanently, as shown in particular by a second curve or profile 27 illustrated through the use of dashed lines.
[0034] FIG. 3 shows a portion of an embodiment variant of a particle agglomerator 1 . The latter is formed with substantially smooth extra-fine wire layers 15 in the manner of a metallic nonwoven, between which are provided structured metal foils 14 , in such a way that channels 16 are formed which extend in the flow direction 7 or along a corresponding axis of the particle agglomerator 1 . Channel narrowing points 17 are formed in the interior of the channels 16 , through the use of guiding faces 32 in the metal foil 14 . The channel narrowing points 17 bring about a (partial) deflection of the exhaust gas flow towards the extra-fine wire layer 15 . In this case, the channel narrowing points 17 or the guide faces 32 are formed in such a way that the channel 16 is not completely closed off but rather a secondary flow 33 is still permitted. As a result of the turning-up of the guide face 32 out of the metal foil 14 , a passage opening 18 is formed which permits the passage of exhaust gas to adjacent channels 16 .
[0035] Furthermore, it is shown in FIG. 3 that the exhaust gas, which contains nitrogen dioxide (NO 2 ), carbon (C) and oxygen (O 2 ), enters into the particle agglomerator 1 and there initiates a conversion of carbon-containing particles 5 contained therein with the nitrogen dioxide, in such a way that nitrogen monoxides (NO), nitrogen (N 2 ), carbon dioxide (CO 2 ) and oxygen (O 2 ) finally leave the particle agglomerator 1 again. The probability of the reaction of nitrogen oxide and soot particles is considerably increased through the use of the particle agglomerator, in such a way that the relatively high conversion rates can be realized with a low pressure loss of the exhaust gas and a blockage of the particle agglomerator is reliably prevented.
[0036] FIG. 4 illustrates a particle agglomerator 1 which firstly has a first zone 8 and thereafter a second zone 9 which extends to a rear end side 10 , in the flow direction 7 . The particle agglomerator 1 is formed over its entire length with smooth extra-fine wire layers 15 and structured metal foils 14 . The metal foils 14 have alternating (oppositely disposed) tapering channel narrowing points 17 , in adjacent channels 16 , which simultaneously permit a secondary flow 33 and bring about a flow of part of the exhaust gas towards the extra-fine wire layer 15 . In this way, the particles 5 , preferably with a diameter 6 of less than 200 nm, are accumulated in or on the walls (or the extra-fine wire layer) of the particle agglomerator 1 and are converted through the use of the nitrogen dioxide which is provided. In this case, the first zone 8 has no oxidatively active coating, while the second zone 9 has a correspondingly provided oxidation catalytic converter 11 , through the use of which new nitrogen oxide is generated again in situ for the regeneration of the particle agglomerator in the rear part.
[0037] It is, of course, possible for various modifications to the system proposed herein to be carried out directly, without departing from the concept of the invention described herein. It is, for example, possible for other particle agglomerators to be used, although it is also possible to position the particle agglomerator 1 , for example, downstream of a turbocharger 13 . The downstream exhaust-gas aftertreatment units 24 can also be combined and supplemented in any desired manner. Furthermore, the invention can also be used with some other internal combustion engine, such as for example a direct-injection spark-ignition engine. | A method for regenerating at least one particle agglomerator of an exhaust gas after-treatment system of an internal combustion engine of a motor vehicle, includes operating the internal combustion engine in at least one operating phase in such a way that a sufficient portion of nitrogen dioxides is directly produced in the exhaust gas in order to ensure a conversion of particles containing carbon in the at least one particle agglomerator. A motor vehicle suitable for carrying out the method is also provided. | 5 |
FIELD OF THE INVENTION
[0001] The field of the invention comprises the use of friction pressure reducing agents to extend the length of vertical, deviated, highly deviated or horizontal intervals that may be gravel packed by means of gravel packing sand (specific gravity of approximately 2.65), man made ceramic proppants (specific gravity 2.65-3.5) or with Low Density Proppant, LDP, also called Low Density Gravel, LDG, and/or by mechanical valves known as Beta Breaker Valves which effectively shorten the fluid path of the wash pipe. The friction pressure reducing agent may be used with either of the LDP/LDG or Beta Breaker Valves or combination of the two.
BACKGROUND OF THE INVENTION
[0002] In the practice of gravel packing long vertical, deviated, highly deviated and horizontal completions, the gravel pack itself may be placed inside a casing or inside an open hole, i.e., no casing completion. The gravel is normally placed in the completion interval by pumping slurry from the surface through a tubing or work-string. The completion typically has a gravel pack packer equipped with a crossover tool that permits the slurry to cross over from the work-string into the annulus between the gravel pack screen and open hole or cased hole.
[0003] The gravel pack screen assembly is located across the zone to be produced and is usually equipped with a wash pipe or inner flow tube. The wash pipe is run almost to the bottom of the screen assembly and is used to take returns through the screen and conduct them back to the casing work-string annulus above the gravel pack packer. Fluids from the slurry travel the path of least resistance, flowing in the annulus between the screen and open hole or casing and inside the screen—wash pipe annulus to enter the end of the wash pipe. The fluids are then returned to the work-string—casing annulus above the grave pack packer through a fluid by-pass in the gravel pack packer service tool, to be circulated back to surface.
[0004] In deviated, highly deviated and horizontal wells the pump rate is normally controlled so that the gravel, proppant or filtering material forms a self propagating dune down the screen. The height of the sand dune is controlled by the fluid velocity across the top of the dune, the viscosity of the carrier fluid, the density difference between the solid particulate filter medium as well as the settling velocity of the gravel, proppant or filter particulate material in the carrier fluid. This initial sand dune normally propagates from the gravel pack packer located inside the casing, down the blank pipe to the screen until it reaches the end of the screen furthest away from the packer.
[0005] The section of the horizontal well at the casing shoe is frequently called the “heel” of the well and the end of the screen furthest from the casing shoe is called the “toe” of the well. This initial dune propagation is commonly referred to as the Alpha Wave.
[0006] When the Alpha Wave reaches the toe of the well the annular area between the top of the screen and the inside diameter, ID, of the casing or open hole is backfilled by fluid entering the screen and depositing the gravel, proppant or filtration material in the void or unfilled area completing the gravel pack. The back filling of the annular area is accomplished by the carrier fluid entering the screen—washpipe annulus, as close to the end of the wash pipe as possible, because of the fluid dynamics seeking the path of least resistance, and depositing the gravel or filtration media in the annular area. The back filling of the top part of the annular area is commonly known in the industry as the Beta Wave.
[0007] In vertical wells and deviated wells the gravel or filtration material may not form an Alpha or Beta wave and may fall or be transported vertically with the carrier fluid to the bottom of the well and fill from the bottom up.
[0008] As the completion interval lengthens the friction pressure increases in the open hole—screen annulus, the screen—washpipe annulus and the washpipe. The increased completion length results in an increase in friction pressure for a given pump rate. Eventually the increase in pressure may reach a level that exceeds the formation parting pressure, also called the formation fracturing pressure, which then prevents further placement of gravel and causes an incomplete fill up of the screen—casing or screen—open hole annulus.
[0009] The fluid pressure working at various points is sum of all of the friction pressure components and the hydrostatic pressure. The hydrostatic pressure is the sum of the carrier fluid density plus the density the gravel or filtration media added to the carrier fluid.
[0010] The term “Equivalent Circulating Density”, ECD, is applied to describe the combination of friction pressure and hydrostatic pressure component of the fluid flow paths. Computer modeling is frequently performed to calculate the ECD at various critical points in a placement of the gravel or filtration media.
[0011] Another method practiced to extend the reach of placing gravel, proppant or filtration media (the term “gravel as used herein intending to cover all these terms) in long sections of highly deviated or horizontal gravel packed wells is to use light weight (low density) gravel, proppant or filtration material.
[0012] When the gravel is added to the completion brine carrier fluid, it will increase the apparent density of the carrier fluid by the relationship of:
[0000] Density of the slurry, lbs/gal=(Mix Ratio of gravel, in lbs added per gallon)*(Density of the carrier fluid, ppg)/(1/(s.g. of the gravel*8.34))*(Mix Ratio of the gravel, in lbs added per gallon).
[0013] Reducing the specific gravity of the gravel will produce a lower slurry density at a given concentration as demonstrated in Table 1 below of Slurry Density for Various Gravel Mix Ratios and Gravel Densities:
[0000]
TABLE 1
Slurry Density for Various Gravel Mix Ratios and Gravel Densities
Gravel s.g. 2.65
Gravel s.g. 1.67
Lbs. added
Lbs. added
Base Fluid
1 ppa
10 ppa
1 ppa
10 ppa
8.5 ppg
9.9 ppg
12.73 ppg
8.86
10.76
9.5 ppg
10.04 ppg
13.42 ppg
9.80 ppg
11.34 ppg
10.5 ppg
11.00 ppg
14.11 ppg
10.73 ppg
11.93 ppg
[0014] The use of Low Density Proppant, LDP, or Gravel for gravel packing has several advantages. It helps to reduce the Hydrostatic Pressure (HP) of the slurry. The use of LDP permits the placement of a large volume of gravel at the same slurry density, thereby reducing the time required to gravel pack the annular volume, and lower the pump rates needed to propagate the Alpha and Beta Waves, which in turn, reduces the friction pressure of the gravel packing operation.
[0015] Technology using mechanical valves to shorten the length of the washpipe as the Beta Wave is placed has been patented and is known as a Beta Breaker and is disclosed under U.S. Pat. No. 6,311,722. Other references to this device and its application are found as follows: “Beta-wave Pressure Control Enables Extended-Reach Horizontal Gravel Packs,” Martin P. Coronado, SPE, and T. Gary Corbett, SPE, both of Baker Oil Tools Society of Petroleum Engineers Inc., 2001.
SUMMARY OF THE INVENTION
[0016] The invention adds a friction reducing agent or agents to a gravel slurry in order to decrease the pumping pressure required for the desired gravel propagation in an annular space around a screen assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a graph of friction pressure loss versus flow rate for a variety of conduit sizes for fresh water;
[0018] FIG. 2 is a graph of friction pressure loss versus flow rate for a variety of conduit sizes for 10 pounds per gallon brine;
[0019] FIG. 3 is a graph of friction pressure loss versus flow rate for a variety of conduit sizes for fresh water with friction reducer;
[0020] FIG. 4 is a graph of friction pressure loss versus flow rate for a variety of conduit sizes for 10 pounds per 1000 gallons mixture of HEC in water;
[0021] FIG. 5 is a graph of friction pressure loss versus flow rate for a variety of conduit sizes for 20 pounds per 1000 gallons mixture of Baker Clean Gel I in water;
[0022] FIG. 6 is a graph of friction pressure loss versus flow rate for a variety of conduit sizes for 20 pounds per 1000 gallons of Guar Polymer in water;
[0023] FIG. 7 is a graph of friction pressure loss versus flow rate for a variety of conduit sizes for 30 pounds per 1000 gallons of Guar Polymer in water; and
[0024] FIG. 8 is a comparison graph of pressure loss versus flow in a 0.43 inch inside diameter tube comparing water to 36 pounds per thousand gallons of XanVis in water.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Friction pressure for Newtonian fluids is normally displayed as a logarithmic function of fluid velocity and friction pressure. FIG. 4 demonstrates typical friction pressures for fresh water and fluid conditioned with 10 lbs/1000 gal of HEC (hydroxy ethyl cellulose) gel.
[0026] Inspection of Curve “I” for the annulus of 2⅞ tubing inside a 5½, 15.5 pounds per foot (ppf) casing at 10 barrels per minute (bpm) indicates a friction pressure of 100 psi/1000 ft. The addition of 10 lbs/1000 gal of HEC, Baker Clean Gel, reduces the friction pressure to approximately 35 psi/1,000 ft., or a 65% reduction in friction pressure.
[0027] The invention uses any of several friction reducing agents. These include polyacrylamides and co-polymers of acrylamides, and polymers, including guar, and derivativized guar, such as hydroxylpropyl guar (HPG), carboxymethlyhydroxypropyl guar (CMHPG), and others, cellulose polymers including hydroxyethylcellulose (HEC), carboxymethylhydroxyethyl cellulose (CMHEC), starch and starch derivatives, biopolymers such as XC and Xanvis and derivatives of biopolymers, and surfactant based systems such as Viscoelastic Surfactant fluids commonly known in the industry as Clear Frac offered by Schlumberger and SurFRAQ offered by Baker Oil Tools.
[0028] Some friction reducers may be preferred over others based on the specific conditions of the gravel pack completion. The type of friction reducer may be selected based on compatibility issues with the completion brine, compatibility issues with the filter cake, the formation temperature and the circulating temperature, the desired shear stability, the ability to form an alpha and beta wave and control the dune height or the ability to transport gravel down alternate flow path tubes, (Shunt Tubes offered by Schlumberger and Direct Pack Tubes offered by Baker Oil Tools).
[0029] The use of a HEC or biopolymers known as XC or Xanvis may provide the desired combination of friction pressure and compatibility characteristics with completion brine and filter cakes to make them preferred in many but not all applications.
[0030] The use of Viscoelastic Surfactants, VES, may be desired in other applications to reduce friction pressure and transport the gravel or filtration media and their use is disclosed in this invention.
[0031] The concentration of the polymers in the industry is usually referred to in pounds of polymer per thousand gallons (pptg), but other concentrations such as weight percent or in the case of Viscoelastic Surfactants, which are liquids their dosage is generally referred to as percent volume to volume (v/v).
[0032] The invention generally sees a preferred range of polymers in a low concentration range of one or less to twenty pptg, but concentrations outside of this range are also seen as having benefit.
[0033] The concentration of the VES is generally preferred in low concentrations of less than 1 percent (v/v), but higher concentrations may be used to achieve the desired friction pressure reduction.
[0034] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below. | The invention adds a friction reducing agent or agents to gravel slurry to decrease pressure required for proper fluid velocities so as to obtain the desired gravel propagation in an annular space around a screen assembly. | 4 |
RELATED APPLICATIONS
This application is a division of application Ser. No. 10/129,589 filed May 7, 2002, now U.S. Pat. No. 6,576,661, which is the National Stage of International Application No. PCT/E00/10620, filed Oct. 27, 2000, which is entitled to the right of priority of German Patent Application No. 199 53 775.5, filed Nov. 9, 1999.
The present invention relates to new active compound combinations composed of known cyclic ketoenols on the one hand and of other known insecticidal active compounds on the other hand and which are highly suitable for controlling animal pests such as insects and undesired acarids.
BACKGROUND OF THE INVENTIONS
The fact that certain cyclic ketoenols have insecticidal and acaricidal properties has already been disclosed (EP-A-528 156). While the activity of these substances is good, it leaves something to be desired in some cases when applied at low rates.
Furthermore, the fact that a large number of heterocycles, organotin compounds, benzoylureas and pyrethroids have insecticidal and acaricidal properties has already been disclosed (cf. WO 93-22 297, WO 93-10 083, DE-A 2 641 343, EP-A-347 488, EP-A-210 487, U.S. Pat. No. 3,264,177 and EP-A-234 045). Again, the action of these substances is not always satisfactory when applied at low rates.
DETAILED DESCRIPTION OF THE INVENTION
It has now been found that compounds of the formula (I)
in which
X represents C 1 -C 6 -alkyl, halogen, C 1 -C 6 -alkoxy or C 1 -C 3 -halogenoalkyl,
Y represents hydrogen, C 1 -C 6 -alkyl, halogen, C 1 -C 6 -alkoxy or C 1 -C 3 -halogenoalkyl,
Z represents C 1 -C 6 -alkyl, halogen or C 1 -C 6 -alkoxy,
n represents an integer from 0-3,
A and B are identical or different and represent hydrogen or optionally halogen-substituted straight-chain or branched C 1 -C 12 -alkyl, C 3 -C 8 -alkenyl, C 3 -C 8 -alkinyl, C 1 -C 10 -alkoxy-C 2 -C 8 -alkyl, C 1 -C 8 -polyalkoxy-C 2 -C 8 -alkyl, C 1 -C 10 -alkylthio-C 2 -C 8 -alkyl, cycloalkyl having 3-8 ring atoms which can be interrupted by oxygen and/or sulphur, and phenyl or phenyl-C 1 -C 6 -alkyl, each of which is optionally substituted by halogen, C 1 -C 6 -alkyl, C 1 -C 6 -halogenoalkyl, C 1 -C 6 -alkoxy, C 1 -C 6 -halogenoalkoxy or nitro,
or in which
A and B together with the carbon atom to which they are bonded form a saturated or unsaturated, 3- to 8-membered ring which is optionally interrupted by oxygen and/or sulphur and optionally substituted by halogen, C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 1 -C 4 -halogenoalkyl, C 1 -C 4 -halogenoalkoxy, C 1 -C 4 -alkylthio or optionally substituted phenyl optionally benzo-fused,
G represents hydrogen (a) or the groups
in which
R 1 represents optionally halogen-substituted C 1 -C 20 -alkyl, C 2 -C 20 -alkenyl, C 1 -C 8 -alkoxy-C 2 -C 8 -alkyl, C 1 -C 8 -alkylthio-C 2 -C 8 -alkyl, C 1 -C 8 -polyalkoxy-C 2 -C 8 -alkyl 8 -alkyl or cycloalkyl having 3-8 ring atoms which can be interrupted by oxygen and/or sulphur atoms,
phenyl which is optionally substituted by halogen, nitro, C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 1 -C 6 -halogenoalkyl or C 1 -C 6 -halogenoalkoxy;
phenyl-C 1 -C 6 -alkyl which is optionally substituted by halogen, C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 1 -C 6 -halogenoalkyl or C 1 -C 6 -halogenoalkoxy,
pyridyl, pyrimidyl, thiazolyl and pyrazolyl, each of which is optionally substituted by halogen and/or C 1 -C 6 -alkyl,
phenoxy-C 1 -C 6 -alkyl which is optionally substituted by halogen and/or C 1 -C 6 -alkyl,
R 2 represents optionally halogen-substituted C 1 -C 20 -alkyl, C 2 -C 20 -alkenyl, C 1 -C 8 -alkoxy-C 2 -C 8 -alkyl or C 1 -C 8 -polyalkoxy-C 2 -C 8 -alkyl,
phenyl or benzyl, each of which is optionally substituted by halogen, nitro, C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy or C 1 -C 6 -halogenoalkyl,
R 3 , R 4 and R 5 independently of one another represent optionally halogen-substituted C 1 -C 8 -alkyl, C 1 -C 8 -alkoxy, C 1 -C 8 -alkylamino, di-(C 1 -C 8 )-alkylamino, C 1 -C 8 -alkylthio, C 2 -C 5 -alkenylthio, C 2 -C 5 -alkinylthio or C 3 -C 7 -cycloalkylthio, or represent phenyl, phenoxy or phenylthio, each of which is optionally substituted by halogen, nitro, cyano, C 1 -C 4 -alkoxy, C 1 -C 4 -halogenoalkoxy, C 1 -C 4 -alkylthio, C 1 -C 4 -halogenoalkylthio, C 1 -C 4 -alkyl or C 1 -C 4 -halogeno-alkyl,
R 6 and R 7 independently of one another represent optionally halogen-substituted C 1 -C 20 -alkyl, C 1 -C 20 -alkoxy, C 2 -C 8 -alkenyl or C 1 -C 20 -alkoxy-C 1 -C 20 -alkyl, or represent phenyl which is optionally substituted by halogen, C 1 -C 20 -halogenoalkyl, C 1 -C 20 -alkyl or C 1 -C 20 -alkoxy, or represent benzyl which is optionally substituted by halogen, C 1 -C 20 -alkyl, C 1 -C 20 -halogenoalkyl or C 1 -C 20 -alkoxy, or together represent a C 2 -C 6 -alkylene ring which is optionally interrupted by oxygen,
and
A)
(thio)phosphates, preferably
1.
azinphos-methyl
disclosed in U.S. 2 758 115
and/or
2.
chlorpyrifos
disclosed in U.S. 3 244 586
and/or
3.
diazinon
disclosed in U.S. 2 754 243
and/or
4.
dimethoate
disclosed in U.S. 2 494 283
and/or
5.
disulfoton
disclosed in DE-A-917 668
and/or
6.
ethion
disclosed in U.S. 2 873 228
and/or
7.
fenitrothion
disclosed in BE-A-594 669
and/or
8.
fenthion
disclosed in DE-A-1 116 656
and/or
9.
isoxathion
disclosed in DE-A-1 567 137
and/or
10.
malathion
disclosed in U.S. 2 578 562
and/or
11.
methidathion
disclosed in DE-A-1 645 982
and/or
12.
oxydemeton-methyl
disclosed in DE-A-947 368
and/or
13.
parathion
disclosed in DE-A-814 152
and/or
14.
parathion-methyl
disclosed in DE-A-814 142
and/or
15.
phenthoate
disclosed in GB-A-834 814
and/or
16.
phorate
disclosed in U.S. 2 586 655
and/or
17.
phosalone
disclosed in DE-A-2 431 192
and/or
18.
phosmet
disclosed in U.S. 2 767 194
and/or
19.
phoxim
disclosed in DE-A-1 238 902
and/or
20.
pirimiphos-methyl
disclosed in DE-A-1 445 949
and/or
21.
profenophos
disclosed in DE-A-2 249 462
and/or
22.
prothiophos
disclosed in DE-A-2 111 414
and/or
23.
tebupirimphos
disclosed in DE-A-3 317 824
and/or
24.
triazophos
disclosed in DE-A-1 299 924
and/or
25.
chlorfenvinphos
disclosed in U.S.-2 956 073
and/or
26.
dichlorphos
disclosed in GB-A-775 085
and/or
27.
dicrotophos
disclosed in BE-A-55 22 84
and/or
28.
mevinphos
disclosed in U.S.-2 685 552
and/or
29.
monocrotophos
disclosed in DE-A-1 964 535
and/or
30.
phosphamidon
disclosed in U.S. 2 908 605
and/or
31.
acephate
disclosed in DE-A-2 014 027
and/or
32.
methamidophos
disclosed in U.S.-3 309 266
and/or
33.
trichlorfon
disclosed in U.S.-2 701 225
and/or
B)
pyrethroids, preferably
34.
acrinathrin
disclosed in EP-A-048 186
and/or
35.
alpha-cypermethrin
disclosed in EP-A-067 461
and/or
36.
betacyfluthrin
disclosed in EP-A-206 149
and/or
37.
cyhalothrin
disclosed in DE-A-2 802 962
and/or
38.
cypermethrin
disclosed in DE-A-2 326 077
and/or
39.
deltamethrin
disclosed in DE-A-2 326 077
and/or
40.
esfenvalerate
disclosed in DE-A-2 737 297
and/or
41.
etofenprox
disclosed in DE-A-3 117 510
and/or
42.
fenpropathrin
disclosed in DE-A-2 231 312
and/or
43.
fenvalerate
disclosed in DE-A-2 335 347
and/or
44.
flucythrinate
disclosed in DE-A-2 757 066
and/or
45.
lambda-cyhalothrin
disclosed in EP-A-106 469
and/or
46.
permethrin
disclosed in DE-A-2 326 077
and/or
47.
tau-fluvalinate
disclosed in EP-A-038 617
and/or
48.
tralomethrin
disclosed in DE-A-2 742 546
and/or
49.
zeta-cypermethrin
disclosed in EP-A-026 542
and/or
C)
carbamates, preferably
50.
carbaryl
disclosed in U.S.-2 903 478
and/or
51.
fenoxycarb
disclosed in EP-A-004 334
and/or
52.
formetanate
disclosed in DE-A-1 169 194
and/or
53.
formetanate hydrochloride
disclosed in DE-A-1 169 194
and/or
54.
methiocarb
disclosed in DE-A-1 162 352
and/or
55.
methomyl
disclosed in U.S.-3 639 620
and/or
56.
oxamyl
disclosed in DE-A-1 768 623
and/or
57.
pirimicarb
disclosed in GB-A-1 181 657
and/or
58.
propoxur
disclosed in DE-A-1 108 202
and/or
59.
thiodicarb
disclosed in DE-A-2 530 439
and/or
D)
benzoylureas, preferably
60.
chlorfluazuron
disclosed in DE-A-2 818 830
and/or
61.
diflubenzuron
disclosed in DE-A 2 123 236
and/or
62.
lufenuron
disclosed in EP-A-179 022
and/or
63.
teflubenzuron
disclosed in EP-A-052 833
and/or
64.
triflumuron
disclosed in DE-A-2 601 780
and/or
E)
macrolides, preferably
65.
ivermectin
disclosed in EP-A-001 689
and/or
66.
emamectin
disclosed in EP-A-089 202
and/or
67.
milbemectin
known from The Pesticide
Manual, 11th Edition,
1997, p. 846
and/or
F)
diacylhydrazines,
preferably
68.
methoxyfenozide
disclosed in EP-A-639 559
and/or
69.
tebufenozide
disclosed in EP-A-339 854
and/or
G)
halogenocycloalkanes,
preferably
70.
endosulfan
disclosed in DE-A-1 015 797
and/or
71.
gamma-HCH
disclosed in U.S. 2,502,258
and/or
H)
acaricides, preferably
72.
fenazaquin
disclosed in EP-A-326 329
and/or
73.
tebufenpyrad
disclosed in EP-A-289 879
and/or
74.
pyrimidifen
disclosed in EP-A-196 524
and/or
75.
triarathene
disclosed in DE-A-2 724 494
and/or
76.
tetradifon
disclosed in U.S. 2 812 281
and/or
77.
propargite
disclosed in U.S. 3 272 854
and/or
78.
hexythiazox
disclosed in DE-A-3 037 105
and/or
79.
bromopropylate
disclosed in U.S. 3 784 696
and/or
80.
2-(acetyloxy)-3-dodecyl-
1,4-naphthalenedione
disclosed in DE-A-2 641 343
and/or
81.
dicofol
disclosed in U.S. 2 812 280
and/or
I)
other compounds such as
82.
amitraz
disclosed in DE-A-2 061 132
and/or
83.
azadirachtin
known from The Pesticide
Manual, 11th Edition,
1997, p. 59
84.
buprofezin
disclosed in DE-A-2 824 126
and/or
85.
quinomethionate
disclosed in DE-A-1 100 372
and/or
86.
thiocyclam hydrogen
oxalate
disclosed in DE-A-2 039 666
and/or
87.
triazamate
disclosed in EP-A-213 718
and/or
88.
Trichogramma spp.
known from The Pesticide
Manual, 11th Edition,
1997, p. 1236
89.
Verticiliium lecanii
known from The Pesticide
Manual, 11th Edition,
1997, p. 1266
90.
fipronil
disclosed in EP-A-295 117
and/or
91.
cyromazine
disclosed in DE-A-2 736 876
and/or
92.
pymetrozin
disclosed in EP-A-314 615
93.
diofenolan
disclosed in DE-A 2 655 910
and/or
94.
indoxacarb
disclosed in WO 92/11249
and/or
95.
pyriproxyfen
disclosed in EP-A-128 648
have very good insecticidal and acaricidal properties.
Preferred active compound combinations are those comprising compounds of the formula (I)
in which
X represents C 1 -C 4 -alkyl, halogen, C 1 -C 4 -alkoxy or C 1 -C 2 -halogenoalkyl,
Y represents hydrogen, C 1 -C 4 -alkyl, halogen, C 1 -C 4 -alkoxy or C 1 -C 2 -halogenoalkyl,
Z represents C 1 -C 4 -alkyl, halogen or C 1 -C 4 -alkoxy,
n represents 0 or 1,
A and B together with the carbon atom to which they are bonded form a saturated 5- to 6-membered ring which is optionally substituted by C 1 -C 4 -alkyl or C 1 -C 4 -alkoxy,
G represents hydrogen (a) or the groups
in which
R 1 represents optionally halogen-substituted C 1 -C 16 -alkyl, C 2 -C 16 -alkenyl, C 1 -C 6 -alkoxy-C 2 -C 6 -alkyl or cycloalkyl having 3-7 ring atoms which can be interrupted by 1 or 2 oxygen and/or sulphur atoms,
phenyl which is optionally substituted by halogen, nitro, C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy, C 1 -C 3 -halogenoalkyl or C 1 -C 3 -halogenoalkoxy,
R 2 represents optionally halogen-substituted C 1 -C 16 -alkyl, C 2 -C 16 -alkenyl or C 1 -C 6 -alkoxy-C 2 -C 6 -alkyl,
phenyl or benzyl, each of which is optionally substituted by halogen, nitro, C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy or C 1 -C 4 -halogenoalkyl,
and at least one active compound of compounds 1 to 95.
Surprisingly, the insecticidal and acaricidal action of the active compound combination according to the invention considerably exceeds the total of the actions of the individual active compounds. A true synergistic effect which could not have been predicted exists, not just a complementation of action.
The active compound combinations according to the invention comprise at least one active compound of compounds 1 to 95, in addition to at least one active compound of the formula (I).
Especially preferred active compound combinations are those comprising the dihydrofuranone derivative of the formula (I-b-1)
and at least one active compound of compounds 1 to 95.
In addition, the active compound combinations may also comprise other fungicidally, acaricidally or insecticidally active components which may be admixed.
If the active compounds are present in the active compound combinations according to the invention in certain weight ratios, the synergistic effect is particularly pronounced. However, the weight ratios of the active compounds in the active compound combinations may be varied within a relatively large range. In general, the combinations according to the invention comprise active compounds of the formula (I) and the other component in the mixing ratios indicated in the table hereinbelow as being preferred and especially preferred.
the mixing ratios are based on weight ratios. The ratio is to be understood as meaning active compound of the formula (I): other component
Especially
Preferred
preferred
Other component
mixing ratio
mixing ratio
2-(Acetyloxy)-3-dodecyl-
10:1 to 1:10
5:1 to 1:5
1,4-naphthalinidone
Acephate
10:1 to 1:10
5:1 to 1:5
Acrinathrin
20:1 to 1:50
10:1 to 1:1
Alpha-cypermethrin
50:1 to 1:5
10:1 to 1:1
Amitraz
5:1 to 1:20
1:1 to 1:10
Azadirachtin
50:1 to 1:5
10:1 to 1:1
Azinphos-methyl
10:1 to 1:10
5:1 to 1:5
Betacyfluthrin
50:1 to 1:5
10:1 to 1:1
Bromopropylate
10:1 to 1:10
5:1 to 1:5
Buprofezin
10:1 to 1:10
5:1 to 1:5
Carbaryl
10:1 to 1:10
5:1 to 1:5
Quinomethionate
10:1 to 1:10
5:1 to 1:5
Chlorfenvinphos
10:1 to 1:10
5:1 to 1:5
Chlorfluazuron
10:1 to 1:10
5:1 to 1:5
Chlorpyrifos
10:1 to 1:10
5:1 to 1:5
Cyhalothrin
50:1 to 1:5
10:1 to 1:1
Cypermethrin
50:1 to 1:5
10:1 to 1:1
Cyromazine
10:1 to 1:10
5:1 to 1:5
Deltamethrin
50:1 to 1:5
10:1 to 1:1
Diazinon
10:1 to 1:10
5:1 to 1:5
Dichlorphos
10:1 to 1:10
5:1 to 1:5
Dicofol
10:1 to 1:10
5:1 to 1:5
Dicrotophos
10:1 to 1:10
5:1 to 1:5
Diflubenzuron
10:1 to 1:10
5:1 to 1:5
Dimethoate
10:1 to 1:10
5:1 to 1:5
Diofenolan
100:1 to 1:2
20:1 to 1:1
Disulfoton
10:1 to 1:10
5:1 to 1:5
Emamectin
50:1 to 1:5
10:1 to 1:1
Endosulfan
10:1 to 1:10
5:1 to 1:5
Esfenvalerate
50:1 to 1:5
10:1 to 1:1
Ethion
10:1 to 1:10
5:1 to 1:5
Etofenprox
10:1 to 1:10
5:1 to 1:5
Fenazaquin
10:1 to 1:10
5:1 to 1:5
Fenitrothion
10:1 to 1:10
5:1 to 1:5
Fenoxycarb
10:1 to 1:10
5:1 to 1:5
Fenpropathrin
10:1 to 1:10
5:1 to 1:5
Fenpyrad (tebufenpyrad)
10:1 to 1:10
5:1 to 1:5
Fenthion
20:1 to 1:10
5:1 to 1:5
Fenvalerate
20:1 to 1:5
10:1 to 1:1
Fipronil
10:1 to 1:10
5:1 to 1:5
Flucythrinate
50:1 to 1:5
10:1 to 1:1
Formetanate
10:1 to 1:10
5:1 to 1:5
Hexyhiazox
20:1 to 1:5
10:1 to 1:2
Indoxacarb
50:1 to 1:5
20:1 to 1:2
Isoxathion
10:1 to 1:10
5:1 to 1:5
Ivermectin
50:1 to 1:5
10:1 to 1:1
Lambda-cyhalothrin
50:1 to 1:5
10:1 to 1:1
Lindane (gamma-HCH)
10:1 to 1:10
5:1 to 1:5
Lufenuron
20:1 to 1:5
10:1 to 1:2
Malathion
10:1 to 1:10
5:1 to 1:5
Methamidophos
10:1 to 1:10
5:1 to 1:5
Methidathion
10:1 to 1:10
5:1 to 1:5
Methiocarb
10:1 to 1:10
5:1 to 1:5
Methomyl
10:1 to 1:10
5:1 to 1:5
Methoxyfenozide
10:1 to 1:10
5:1 to 1:5
Mevinphos
10:1 to 1:10
5:1 to 1:5
Milbemectin
50:1 to 1:5
10:1 to 1:1
Monocrotophos
10:1 to 1:10
5:1 to 1:5
Oxamyl
5:1 to 1:100
1:1 to 1:20
Oxydemeton-methyl
10:1 to 1:10
5:1 to 1:5
Parathion
10:1 to 1:10
5:1 to 1:5
Parathion-methyl
10:1 to 1:10
5:1 to 1:5
Permethrin
10:1 to 1:10
5:1 to 1:5
Phenthoate
10:1 to 1:10
5:1 to 1:5
Phorate
10:1 to 1:10
5:1 to 1:5
Phosalone
10:1 to 1:10
5:1 to 1:5
Phosmet
10:1 to 1:10
5:1 to 1:5
Phosphamidon
10:1 to 1:10
5:1 to 1:5
Phoxim
10:1 to 1:10
5:1 to 1:5
Pirimicarb
40:1 to 1:10
5:1 to 1:5
Pirimiphos-methyl
10:1 to 1:10
5:1 to 1:5
Profenophos
10:1 to 1:10
5:1 to 1:5
Propargite
10:1 to 1:10
5:1 to 1:5
Propoxur
10:1 to 1:10
5:1 to 1:5
Prothiophos
10:1 to 1:10
5:1 to 1:5
Pymetrozin
10:1 to 1:10
5:1 to 1:5
Pyrimidifen
50:1 to 1:5
10:1 to 1:1
Pyriproxyfen
10:1 to 1:10
5:1 to 1:5
Tau-fluvalinate
20:1 to 1:5
10:1 to 1:2
Tebufenozide
10:1 to 1:10
5:1 to 1:5
Tebupirimphos
10:1 to 1:10
5:1 to 1:5
Teflubenzuron
20:1 to 1:5
10:1 to 1:2
Tetradifon
10:1 to 1:10
5:1 to 1:5
Thiocyclam
5:1 to 1:20
1:1 to 1:10
Thiodicarb
5:1 to 1:20
1:1 to 1:10
Tralomethrin
50:1 to 1:5
10:1 to 1:1
Triarathene
5:1 to 1:20
1:1 to 1:10
Triazamate
10:1 to 1:10
5:1 to 1:5
Triazophos
5:1 to 1:20
1:1 to 1:10
Trichlorfon
10:1 to 1:10
5:1 to 1:5
Trichogramma spp.
Triflumuron
10:1 to 1:10
5:1 to 1:5
Verticillium lecanii
Zeta-cypermethrin
50:1 to 1:5
10:1 to 1:2
The active compound combinations according to the invention are suitable for controlling animal pests, preferably arthropods and nematodes, in particular insects and arachnids found in agriculture, in afforestations, in the protection of stored product and materials and in the hygiene sector. They are active against normally sensitive and resistant species, and against all or individual developmental stages. The abovementioned pests include:
From the order of the Isopoda , for example, Oniscus asellus, Armadillidium vulgare, Porcellio scaber.
From the order of the Diplopoda , for example, Blaniulus guttulatus.
From the order of the Chilopoda , for example, Geophilus carpophagus, Scutigera spp.
From the order of the Symphyla , for example, Scutigerella immaculata.
From the order of the Thysanura , for example, Lepisma saccharina.
From the order of the Collembola , for example, Onychiurus armatus.
From the order of the Orthoptera , for example, Acheta domesticus, Gryllotalpa spp., Locusta migratoria migratorioides, Melanoplus spp., Schistocerca gregaria.
From the order of the Blattaria , for example, Blatta orientalis, Periplaneta americana, Leucophaea maderae, Blattella germanica.
From the order of the Dermaptera , for example, Forficula auricularia.
From the order of the Isoptera , for example, Reticulitermes spp.
From the order of the Phthiraptera , for example, Pediculus humanus corporis, Haematopinus spp., Linognathus spp., Trichodectes spp., Damalinia spp.
From the order of the Thysanoptera , for example, Hercinothrips femoralis, Thrips tabaci, Thrips palmi, Frankliniella accidentalis.
From the order of the Heteroptera , for example, Eurygaster spp., Dysdercus intermedius, Piesma quadrata, Cimex lectularius, Rhodnius prolixus, Triatoma spp.
From the order of the Homoptera , for example, Aleurodes brassicae, Bemisia tabaci, Trialeurodes vaporariorum, Aphis gossypii, Brevicoryne brassicae, Cryptomyzus ribis, Aphis fabae, Aphis pomi, Eriosoma lanigerum, Hyalopterus arundinis, Phylloxera vastatrix, Pemphigus spp., Macrosiphum avenae, Myzus spp., Phorodon humuli, Rhopalosiphum padi, Empoasca spp., Euscelis bilobatus, Nephotettix cincticeps, Lecanium corni, Saissetia oleae, Laodelphax striatellus, Nilaparvata lugens, Aonidiella aurantii, Aspidiotus hederae, Pseudococcus spp., Psylla spp.
From the order of the Lepidoptera , for example, Pectinophora gossypiella, Bupalus piniarius, Cheimatobia brumata, Lithocolletis blancardella, Hyponomeuta padella, Plutella xylostella, Malacosoma neustria, Euproctis chrysorrhoea, Lymantria spp., Bucculatrix thurberiella, Phyllocnistis citrella, Agrotis spp., Euxoa spp., Feltia spp., Earias insulana, Heliothis spp., Mamestra brassicae, Panolis flammea, Spodoptera spp., Trichoplusia ni, Carpocapsa pomonella, Pieris spp., Chilo spp., Pyrausta nubilalis, Ephestia kuehniella, Galleria mellonella, Tineola bisselliella, Tinea pellionella, Hofmannophila pseudospretella, Cacoecia podana, Capua reticulana, Choristoneura fumiferana, Clysia ambiguella, Homona magnanima, Tortrix viridana, Cnaphalocerus spp., Oulema oryzae.
From the order of the Coleoptera , for example, Anobium punctatum, Rhizopertha dominica, Bruchidius obtectus, Acanthoscelides obtectus, Hylotrupes bajulus, Agelastica alni, Leptinotarsa decemlineata, Phaedon cochleariae, Diabrotica spp., Psylliodes chrysocephala, Epilachna varivestis, Atomaria spp., Oryzaephilus surinamensis, Anthonomus spp., Sitophilus spp., Otiorrhynchus sulcatus, Cosmopolites sordidus, Ceuthorrhynchus assimilis, Hypera postica, Dermestes spp., Trogoderma spp., Anthrenus spp., Attagenus spp., Lyctus spp., Meligethes aeneus, Ptinus spp., Niptus hololeucus, Gibbium psylloides, Tribolium spp., Tenebrio molitor, Agriotes spp., Conoderus spp., Melolontha melolontha, Amphimallon solstitialis, Costelytra zealandica, Lissorhoptrus oryzophilus.
From the order of the Hymenoptera , for example, Diprion spp., Hoplocampa spp., Lasius spp., Monomorium pharaonis, Vespa spp.
From the order of the Diptera , for example, Aedes spp., Anopheles spp., Culex spp., Drosophila melanogaster, Musca spp., Fannia spp., Calliphora erythrocephala, Lucilia spp., Chrysomyia spp., Cuterebra spp., Gastrophilus spp., Hyppobosca spp., Stomoxys spp., Oestrus spp., Hypoderma spp., Tabanus spp., Tannia spp., Bibio hortulanus, Oscinella frit, Phorbia spp., Pegomyia hyoscyami, Ceratitis capitata, Dacus oleae, Tipula paludosa, Hylemyia spp., Liriomyza spp.
From the order of the Siphonaptera , for example, Xenopsylla cheopis, Ceratophyllus spp.
From the class of the Arachnida , for example, Scorpio maurus, Latrodectus mactans, Acarus siro, Argas spp., Ornithodoros spp., Dermanyssus gallinae, Eriophyes ribis, Phyllocoptruta oleivora, Boophilus spp., Rhipicephalus spp., Amblyomma spp., Hyalomma spp., Ixodes spp., Psoroptes spp., Chorioptes spp., Sarcoptes spp., Tarsonemus spp., Bryobia praetiosa, Panonychus spp., Tetranychus spp., Hemitarsonemus spp., Brevipalpus spp.
The plant-parasitic nematodes include, for example, Pratylenchus spp., Radopholus similis, Ditylenchus dipsaci, Tylenchulus semipenetrans, Heterodera spp., Globodera spp., Meloidogyne spp., Aphelenchoides spp., Longidorus spp., Xiphinema spp., Trichodorus spp., Bursaphelenchus spp.
The active compound combinations can be converted into the customary formulations such as solutions, emulsions, wettable powders, suspensions, powders, dusts, pastes, soluble powders, granules, suspension-emulsion concentrates, natural and synthetic materials impregnated with active compound, and microencapsulations in polymeric materials.
These formulations are produced in a known manner, for example by mixing the active compounds with extenders, that is, liquid solvents and/or solid carriers, optionally with the use of surfactants, that is, emulsifiers and/or dispersants, and/or foam formers.
In the case of the use of water as an extender, organic solvents can, for example, also be used as cosolvents. The following are essentially suitable as liquid solvents: aromatics such as xylene, toluene or alkylnaphthalenes, chlorinated aromatics or chlorinated aliphatic hydrocarbons such as chlorobenzenes, chloroethylenes or methylene chloride, aliphatic hydrocarbons such as cyclohexane or paraffins, for example mineral oil fractions, mineral and vegetable oils, alcohols such as butanol or glycol and their ethers and esters, ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone or cyclohexanone, strongly polar solvents such as dimethylformamide and dimethyl sulphoxide, or else water.
Suitable solid carriers are:
for example ammonium salts and ground natural minerals such as kaolins, clays, talc, chalk, quartz, attapulgite, montmorillonite or diatomaceous earth, and ground synthetic materials such as highly-disperse silica, alumina and silicates; suitable solid carriers for granules are: for example crushed and fractionated natural rocks such as calcite, marble, pumice, sepiolite and dolomite, or else synthetic granules of inorganic and organic meals, and granules of organic material such as sawdust, coconut shells, maize cobs and tobacco stalks; suitable emulsifiers and/or foam formers are: for example nonionic and anionic emulsifiers such as polyoxyethylene fatty acid esters, polyoxyethylene fatty alcohol ethers, for example alkylaryl polyglycol ethers, alkylsulphonates, alkyl sulphates, arylsulphonates, or else protein hydrolysates; suitable dispersants are: for example lignin-sulphite waste liquors and methylcellulose.
Adhesives such as carboxymethylcellulose and natural and synthetic polymers in the form of powders, granules or latices, such as gum arabic, polyvinyl alcohol and polyvinyl acetate, or else natural phospholipids such as cephalins and lecithins and synthetic phospholipids can be used in the formulations. Other additives can be mineral and vegetable oils.
It is possible to use colorants such as inorganic pigments, for example iron oxide, titanium oxide and Prussian Blue, and organic colorants such alizarin colorants, azo colorants and metal phthalocyanine colorants, and trace nutrients such as salts of iron, manganese, boron, copper, cobalt, molybdenum and zinc.
The formulations generally comprise between 0.1 and 95% by weight of active compound, preferably between 0.5 and 90%.
The active compound combinations according to the invention can be present in their commercially available formulations and in the use forms, prepared from these formulations, as a mixture with other active compounds, such as insecticides, attractants, sterilants, bactericides, acaricides, nematicides, fungicides, growth-regulating substances or herbicides. The insecticides include, for example, phosphates, carbamates, carboxylates, chlorinated hydrocarbons, phenylureas and substances produced by microorganisms.
Mixtures with other known active compounds such as herbicides or with fertilizers and growth regulators are also possible.
When used as insecticides, the active compound combinations according to the invention can furthermore be present in their commercially available formulations and in the use forms, prepared from these formulations, as a mixture with synergists. Synergists are compounds which increase the action of the active compounds, without it being necessary for the synergist added to be active itself.
The active compound content of the use forms prepared from the commercially available formulations can vary within wide limits. The active compound concentration of the use forms can be from 0.0000001 to 95% by weight of active compound, preferably between 0.0001 and 1% by weight.
The compounds are employed in a customary manner appropriate for the use forms.
When used against hygiene pests and stored-product pests, the active compound combinations are distinguished by an excellent residual action on wood and clay as well as a good stability to alkali on limed substrates.
The active compound combinations according to the invention are not only active against plant pests, hygiene pests and stored-product pests, but also, in the veterinary medicine sector, against animal parasites (ectoparasites) such as hard ticks, soft ticks, mange mites, harvest mites, flies (stinging and licking), parasitizing fly larvae, lice, hair lice, bird lice and fleas. These parasites include:
From the order of the Anoplurida , for example, Haematopinus spp., Linognathus spp., Pediculus spp., Phtirus spp., Solenopotes spp.
From the order of the Mallophagida and the suborders Amblycerina and Ischnocerina , for example, Trimenopon spp., Menopon spp., Trinoton spp., Bovicola spp., Werneckiella spp., Lepikentron spp., Damalina spp., Trichodectes spp., Felicola spp.
From the order Diptera and the suborders Nematocerina and Brachycerina , for example, Aedes spp., Anopheles spp., Culex spp., Simulium spp., Eusimulium spp., Phlebotomus spp., Lutzomyia spp., Culicoides spp., Chrysops spp., Hybomitra spp., Atylotus spp., Tabanus spp., Haematopota spp., Philipomyia spp., Braula spp., Musca spp., Hydrotaea spp., Stomoxys spp., Haematobia spp., Morellia spp., Fannia spp., Glossina spp., Calliphora spp., Lucilia spp., Chrysomyia spp., Wohlfahrtia spp., Sarcophaga spp., Oestrus spp., Hypoderma spp., Gasterophilus spp., Hippobosca spp., Lipoptena spp., Melophagus spp.
From the order of the Siphonapterida , for example, Pulex spp., Ctenocephalides spp., Xenopsylla spp., Ceratophyllus spp.
From the order of the Heteropterida , for example, Cimex spp., Triatoma spp., Rhodnius spp., Panstrongylus spp.
From the order of the Blattarida , for example, Blatta orientalis, Periplaneta americana, Blattella germanica, Supella spp.
From the subclass of the Acaria ( Acarida ) and the order of the Meta - and Mesostigmata , for example, Argas spp., Omithodorus spp., Otobius spp., Ixodes spp., Amblyomma spp., Boophilus spp., Dermacentor spp., Haemophysalis spp., Hyalomma spp., Rhipicephalus spp., Dermanyssus spp., Raillietia spp., Pneumonyssus spp., Sternostoma spp., Varroa spp.
From the order of the Actinedida ( Prostigmata ) and Acaridida ( Astigmata ), for example, Acarapis spp., Cheyletiella spp., Ornithocheyletia spp., Myobia spp., Psorergates spp., Demodex spp., Trombicula spp., Listrophorus spp., Acarus spp., Tyrophagus spp., Caloglyphus spp., Hypodectes spp., Pterolichus spp., Psoroptes spp., Chorioptes spp., Otodectes spp., Sarcoptes spp., Notoedres spp., Knemidocoptes spp., Cytodites spp., Laminosioptes spp.
The active compound combinations according to the invention are also suitable for controlling arthropods which attack agricultural livestock such as, for example, cattle, sheep, goats, horses, pigs, donkeys, camels, buffaloes, rabbits, chickens, turkeys, ducks, geese, honey bees, other domestic animals such as, for example, dogs, cats, caged birds, aquarium fish and so-called experimental animals such as, for example, hamsters, guinea pigs, rats and mice. By controlling these arthropods, cases of death and reductions in productivity (for meat, milk, wool, hides, eggs, honey and the like) should be diminished, so that more economical and simpler animal husbandry is possible by the use of the active compound combinations according to the invention.
The active compound combinations according to the invention are used in the veterinary sector in a known manner by enteral administration in the form of, for example, tablets, capsules, potions, drenches, granules, pastes, boluses, the feed-through method, suppositories, by parenteral administration such as, for example, by injections (intramuscularly, subcutaneously, intravenously, intraperitoneally and the like), implants, by nasal administration, by dermal administration in the form of, for example, immersing or dipping, spraying, pouring-on, spotting-on, washing, dusting, and with the aid of active-compound-comprising moulded articles such as collars, ear tags, tail tags, limb bands, halters, marking devices and the like.
When used for cattle, poultry, domestic animals and the like, the active compound combinations can be applied as formulations (for example powders, emulsions, flowables) comprising the active compounds in an amount of 1 to 80% by weight, either directly or after 100- to 10,000-fold dilution, or they may be used as a chemical dip.
Moreover, it has been found that the active compound combinations according to the invention show a potent insecticidal action against insects which destroy industrial materials.
The following insects may be mentioned by way of example and with preference, but not by way of limitation:
Beetles such as
Hylotrupes bajulus, Chlorophorus pilosis, Anobium punctatum, Xestobium rufovillosum, Ptilinus pecticornis, Dendrobium pertinex, Ernobius mollis, Priobium carpini, Lyctus brunneus, Lyctus africanus, Lyctus planicollis, Lyctus linearis, Lyctus pubescens, Trogoxylon aequale, Minthes rugicollis, Xyleborus spec., Tryptodendron spec., Apate monachus, Bostrychus capucins, Heterobostrychus brunneus, Sinoxylon spec., Dinoderus minutus.
Dermapterans such as
Sirex juvencus, Urocerus gigas, Urocerus gigas taignus, Urocerus augur.
Termites such as
Kalotermes flavicollis, Cryptotermes brevis, Heterotermes indicola, Reticulitermes flavipes, Reticulitermes santonensis, Reticulitermes lucifugus, Mastotermes darwiniensis, Zootermopsis nevadensis, Coptotermes formosanus.
Bristle tails such as Lepisma saccharina.
Industrial materials in the present context are understood as meaning non-living materials such as, preferably, polymers, adhesives, glues, paper and board, leather, wood, timber products and paints.
The material which is to be protected from insect attack is very especially preferably wood and timber products.
Wood and timber products which can be protected by the composition according to the invention, or mixtures comprising it, are to be understood as meaning, for example:
Construction timber, wooden beams, railway sleepers, bridge components, jetties, vehicles made of wood, boxes, pallets, containers, telephone poles, wood lagging, windows and doors made of wood, plywood, clipboard, joinery, or timber products which quite generally are used in house construction or building joinery.
The active compound combinations can be used as such, in the form of concentrates or generally customary formulations such as powders, granules, solutions, suspensions, emulsions or pastes.
The abovementioned formulations can be prepared in a manner known per se, for example by mixing the active compounds with at least one solvent or diluent, emulsifier, dispersant and/or binder or fixative, water repellant, if desired desiccants and UV stabilizers, and if desired colorants and pigments and other processing auxiliaries.
The insecticidal compositions or concentrates used for protecting wood and timber products comprise the active compound according to the invention in a concentration of 0.0001 to 95% by weight, in particular 0.001 to 60% by weight.
The amount of composition or concentrate employed depends on the species and the abundance of the insects and on the medium. The optimal quantity to be employed can be determined in each case by test series upon application. In general, however, it will suffice to employ 0.0001 to 20% by weight, preferably 0.001 to 10% by weight, of the active compound, based on the material to be protected.
A suitable solvent and/or diluent is an organochemical solvent or solvent mixture and/or an oily or oil-type organochemical solvent or solvent mixture of low volatility and/or a polar organochemical solvent or solvent mixture and/or water and, if appropriate, an emulsifier and/or wetter.
Organochemical solvents which are preferably employed are oily or oil-type solvents with an evaporation number of above 35 and a flash point of above 30° C., preferably above 45° C. Such oily and oil-type solvents which are insoluble in water and of low volatility and which are used are suitable mineral oils or their aromatic fractions or mineral-oil-containing solvent mixtures, preferably white spirit, petroleum and/or alkylbenzene.
Mineral oils which are advantageously used are those with a boiling range of 170 to 220° C., white spirit with a boiling range of 170 to 220° C., spindle oil with a boiling range of 250 to 350° C., petroleum and aromatics with a boiling range of 160 to 280° C., oil of terpentine, and the like.
In a preferred embodiment, liquid aliphatic hydrocarbons with a boiling range of 180 to 210° C. or high-boiling mixtures of aromatic and aliphatic hydrocarbons with a boiling range of 180 to 220° C. and/or spindle oil and/or monochloronaphthalene, preferably α-monochloronaphthalene are used.
The organic oily or oil-type solvents of low volatility and with an evaporation number of above 35 and a flash point of above 30° C., preferably above 45° C., can be replaced in part by organochemical solvents of high or medium volatility, with the proviso that the solvent mixture also has an evaporation number of above 35 and a flash point of above 30° C., preferably above 45° C., and that the insecticide/fungicide mixture is soluble or emulsifiable in this solvent mixture.
In a preferred embodiment, some of the organochemical solvent or solvent mixture is replaced by an aliphatic polar organochemical solvent or solvent mixture. Aliphatic organochemical solvents which contain hydroxyl and/or ester and/or ether groups are preferably used, such as, for example, glycol ethers, esters or the like.
Organochemical binders used for the purposes of the present invention are the synthetic resins and/or binding drying oils which are known per se and which can be diluted in water and/or dissolved or dispersed or emulsified in the organochemical solvents employed, in particular binders composed of, or comprising, an acrylate resin, a vinyl resin, for example polyvinyl acetate, polyester resin, polycondensation or polyaddition resin, polyurethane resin, alkyd resin or modified alkyd resin, phenol resin, hydrocarbon resin such as indene/coumarone resin, silicone resin, drying vegetable and/or drying oils and/or physically drying binders based on a natural and/or synthetic resin.
The synthetic resin employed as binder can be employed in the form of an emulsion, dispersion or solution. Bitumen or bituminous substances may also be used as binders, in amounts of up to 10% by weight. In addition, colorants, pigments, water repellants, odour-masking agents, and inhibitors or anticorrosive agents and the like, all of which are known per se, can be employed.
In accordance with the invention, the composition or the concentrate preferably comprises, as organochemical binders, at least one alkyl resin or modified alkyl resin and/or a drying vegetable oil. Alkyd resins which are preferably used in accordance with the invention are those with an oil content of over 45% by weight, preferably 50 to 68% by weight.
Some or all of the abovementioned binder can be replaced by a fixative (mixture) or plasticizer (mixture). These additives are intended to prevent volatilization of the active compounds, and also crystallization or precipitation. They preferably replace 0.01 to 30% of the binder (based on 100% of binder employed).
The plasticizers are from the chemical classes of the phthalic esters, such as dibutyl phthalate, dioctyl phthalate or benzyl butyl phthalate, phosphoric esters such as tributyl phosphate, adipic esters such as di-(2-ethylhexyl)-adipate, stearates such as butyl stearate or amyl stearate, oleates such as butyl oleate, glycerol ethers or higher-molecular-weight glycol ethers, glycerol esters and p-toluenesulphonic esters.
Fixatives are based chemically on polyvinyl alkyl ethers such as, for example, polyvinyl methyl ether, or ketones such as benzophenone and ethylenebenzophenone.
Other suitable solvents or diluents are, in particular, also water, if appropriate as a mixture with one or more of the abovementioned organochemical solvents or diluents, emulsifiers and dispersants.
Particularly effective timber protection is achieved by industrial-scale impregnating processes, for example the vacuum, double-vacuum or pressure processes.
The active compound combinations according to the invention can also be employed for protecting objects which come into contact with saltwater or brackish water, such as hulls, screens, nets, buildings, moorings and signalling systems, from fouling.
Fouling by sessile Oligochaeta, such as Serpulidae, and by shells and species from the Ledamorpha group (goose barnacles), such as various Lepas and Scalpellum species, or by species from the Balanomorpha group (acorn barnacles), such as Balanus or Pollicipes species, increases the frictional drag of ships and, as a consequence, leads to a marked increase in operation costs owing to higher energy consumption and additionally frequent residence in the dry dock.
Apart from fouling by algae, for example Ectocarpus sp. and Ceramium sp., fouling by sessile Entomostraka groups, which come under the generic term Cirripedia (cirriped crustaceans), is of particular importance.
Surprisingly, it has now been found that the active compound combinations according to the invention have an outstanding antifouling action.
Using the active compound combinations according to the invention, the use of heavy metals such as, for example, in bis(trialkyltin) sulphides, tri-n-butyltin laurate, tri-n-butyltin chloride, copper(I) oxide, triethyltin chloride, tri-n-butyl(2-phenyl-4-chlorophenoxy)tin, tributyltin oxide, molybdenum disulphide, antimony oxide, polymeric butyl titanate, phenyl-(bispyridine)-bismuth chloride, tri-n-butyltin fluoride, manganese ethylenebisthiocarbamate, zinc dimethyldithiocarbamate, zinc ethylenebisthiocarbamate, zinc salts and copper salts of 2-pyridinethiol 1-oxide, bisdimethyldithiocarbamoylzinc ethylenebisthiocarbamate, zinc oxide, copper(I) ethylene-bisdithiocarbamate, copper thiocyanate, copper naphthenate and tributyltin halides can be dispensed with, or the concentration of these compounds substantially reduced.
If appropriate, the ready-to-use antifouling paints can additionally comprise other active compounds, preferably algicides, fungicides, herbicides, molluscicides, or other antifouling active compounds.
Preferably suitable components in combinations with the antifouling compositions according to the invention are:
algicides such as
2-tert.-butylamino-4-cyclopropylamino-6-methylthio-1,3,5-triazine, dichlorophen, diuron, endothal, fentine acetate, isoproturon, methabenzthiazuron, oxyfluorfen, quinoclamine and terbutryn;
fungicides such as
benzo[b]thiophenecarboxylic acid cyclohexylamide S,S-dioxide, dichlofluanid, fluor-folpet, 3-iodo-2-propinyl butylcarbamate, tolylfluanid and azoles such as azaconazole, cyproconazole, epoxyconazole, hexaconazole, metconazole, propiconazole and tebuconazole;
molluscicides such as fentin acetate, metaldehyde, methiocarb, niclosamid, thiodicarb and trimethacarb;
or conventional antifouling active compounds such as
4,5-dichloro-2-octyl-4-isothiazolin-3-one, diiodomethylparatryl sulfone, 2-(N,N-di-methylthiocarbamoylthio)-5-nitrothiazyl, potassium, copper, sodium and zinc salts of 2-pyridinethiol 1-oxide, pyridine-triphenylborane, tetrabutyldistannoxane, 2,3,5,6-tetrachloro-4-(methylsulfonyl)-pyridine, 2,4,5,6-tetrachloroisophthalonitrile, tetramethylthiuram disulfide and 2,4,6-trichlorophenylmaleiim
The antifouling compositions used comprise the active compound combinations according to the invention in a concentration of 0.001 to 50% by weight, in particular 0.01 to 20% by weight.
Moreover, the antifouling compositions according to the invention comprise the customary components such as, for example, those described in Ungerer, Chem. Ind . 1985, 37, 730-732 and Williams, Antifouling Marine Coatings, Noyes, Park Ridge, 1973.
Besides the algicidal, fungicidal, molluscicidal active compounds and insecticidal active compounds according to the invention, antifouling paints comprise, in particular, binders.
Examples of recognized binders are polyvinyl chloride in a solvent system, chlorinated rubber in a solvent system, acrylic resins in a solvent system, in particular in an aqueous system, vinyl chloride/vinyl acetate copolymer systems in the form of aqueous dispersions or in the form of organic solvent systems, butadiene/styrene/acrylonitrile rubbers, drying oils such as linseed oil, resin esters or modified hardened resins in combination with tar or bitumens, asphalt and epoxy compounds, small amounts of chlorine rubber, chlorinated polypropylene and vinyl resins.
If appropriate, paints also comprise inorganic pigments, organic pigments or colorants which are preferably soluble in salt water. Paints may furthermore comprise materials such as colophonium to allow controlled release of the active compounds. Furthermore, the paints may comprise plasticizers, modifiers which affect the rheological properties and other conventional constituents. The compounds according to the invention or the abovementioned mixtures may also be incorporated into self-polishing antifouling systems.
The active compound combinations are also suitable for controlling animal pests, in particular insects, arachnids and mites, which are found in enclosed spaces such as, for example, dwellings, factory halls, offices, vehicle cabins and the like. They can be employed in domestic insecticide products for controlling these pests. They are active against sensitive and resistant species and against all developmental stages. These pests include:
From the order of the Scorpionidea , for example, Buthus occitanus.
From the order of the Acarina , for example, Argas persicus, Argas reflexus, Bryobia ssp., Dermanyssus gallinae, Glyciphagus domesticus, Omithodorus moubat, Rhipicephalus sanguineus, Trombicula alfreddugesi, Neutrombicula autumnalis, Dermatophagoides pteronissimus, Dermatophagoides forinae.
From the order of the Araneae , for example, Aviculariidae, Araneidae.
From the order of the Opiliones , for example, Pseudoscorpiones chelifer, Pseudoscorpiones cheiridium, Opiliones phalangium.
From the order of the Isopoda , for example, Oniscus asellus, Porcellio scaber.
From the order of the Diplopoda , for example, Blaniulus guttulatus, Polydesmus spp.
From the order of the Chilopoda , for example, Geophilus spp.
From the order of the Zygentoma , for example, Ctenolepisma spp., Lepisma saccharina, Lepismodes inquilinus.
From the order of the Blattaria , for example, Blatta orientalies, Blattella germanica, Blattella asahinai, Leucophaea maderae, Panchlora spp., Parcoblatta spp., Periplaneta australasiae, Periplaneta americana, Periplaneta brunnea, Periplaneta fuliginosa, Supella longipalpa.
From the order of the Saltatoria , for example, Acheta domesticus.
From the order of the Dermaptera , for example, Forficula auricularia.
From the order of the Isoptera , for example, Kalotermes spp., Reticulitermes spp.
From the order of the Psocoptera , for example, Lepinatus spp., Liposcelis spp.
From the order of the Coleptera , for example, Anthrenus spp., Attagenus spp., Dermestes spp., Latheticus oryzae, Necrobia spp., Ptinus spp., Rhizopertha dominica, Sitophilus granarius, Sitophilus oryzae, Sitophilus zeamais, Stegobium paniceum.
From the order of the Diptera , for example, Aedes aegypti, Aedes albopictus, Aedes taeniorhynchus, Anopheles spp., Calliphora erythrocephala, Chrysozona pluvialis, Culex quinquefasciatus, Culex pipiens, Culex tarsalis, Drosophila spp., Fannia canicularis, Musca domestica, Phlebotomus spp., Sarcophaga carnaria, Simulium spp., Stomoxys calcitrans, Tipula paludosa.
From the order of the Lepidoptera , for example, Achroia grisella, Galleria mellonella, Plodia interpunctella, Tinea cloacella, Tinea pellionella, Tineola bisselliella.
From the order of the Siphonaptera , for example, Ctenocephalides canis, Ctenocephalides felis, Pulex irritans, Tunga penetrans, Xenopsylla cheopis.
From the order of the Hymenoptera , for example, Camponotus herculeanus, Lasius fuliginosus, Lasius niger, Lasius umbratus, Monomorium pharaonis, Paravespula spp., Tetramorium caespitum.
From the order of the Anoplura , for example, Pediculus humanus capitis, Pediculus humanus corporis, Phthirus pubis.
From the order of the Heteroptera , for example, Cimex hemipterus, Cimex lectularius, Rhodinus prolixus, Triatoma infestans.
They are used as aerosols, pressure-free spray products, for example pump and atomizer sprays, automatic fogging systems, foggers, foams, gels, evaporator products with evaporator tablets made of cellulose or polymer, liquid evaporators, gel and membrane evaporators, propeller-driven evaporators, energy-free, or passive, evaporation systems, moth papers, moth bags and moth gels, as granules or dusts, in baits for spreading or in bait stations.
All plants and plant parts can be treated in accordance with the invention. Plants are to be understood as meaning in the present context all plants and plant populations such as desired and undesired wild plants or crop plants (inclusive of naturally occurring crop plants). Crop plants can be plants which can be obtained by conventional plant breeding and optimization methods or by biotechnological and recombinant methods or by combinations of these methods, inclusive of the transgenic plants and inclusive of the plant varieties protectable or not protectable by plant breeders' rights, such as shoot, leaf, flower and root, examples which may be mentioned being leaves, needles, stalks, stems, flowers, fruit bodies, fruits, seeds, roots, tubers and rhizomes. The plant parts also include harvested material, and vegetative and generative propagation material, for example cuttings, tubers, rhizomes, offsets and seeds.
Treatment according to the invention of the plants and plant parts with the active compounds is carried out directly or by allowing the compounds to act on the surroundings, environment or storage space by the customary treatment methods, for example by immersion, spraying, evaporation, fogging, scattering, painting on and, in the case of propagation material, in particular in the case of seed, also by applying one or more coats.
The good insecticidal and acaricidal action of the active compound combinations according to the invention can be seen from the examples which follow. While the individual active compounds show weaknesses in their action, the combinations show an action which exceeds a simple sum of actions.
A synergistic effect in insecticides and acaricides is always present when the action of the active compound combinations exceeds the total of the actions of the active compounds when applied individually.
The expected action for a given combination of two active compounds can be calculated as follows, using the formula of S. R. Colby, Weeds 15 (1967), 20-22:
If
X is the efficacy when employing active compound A at an application rate of m g/ha or in a concentration of m ppm,
Y is the efficacy when employing active compound B at an application rate of n g/ha or in a concentration of n ppm and
E is the efficacy when employing active compounds A and B at application rates of m and n g/ha or in a concentration of m and n ppm,
then E = X + Y - X · Y 100
The efficacy is determined in %. 0% means an efficacy which corresponds to that of the control, while an efficacy of 100% means that no infection/infestation is observed.
If the actual action exceeds the calculated value, the action of the combination is superadditive, i.e. a synergistic effect is present. In this case, the actually observed efficacy must exceed the value calculated using the above formula for the expected efficacy (E).
USE EXAMPLES
Example A
Heliothis virescens Test
solvent:
7 parts by weight of dimethylformamide
emulsifier:
1 part by weight of alkylaryl polyglycol ether
To produce a suitable active compound preparation, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with emulsifier-containing water to the desired concentration.
Soya bean shoots ( Glycine max ) are treated by immersion in the active compound preparation of the desired concentration and are populated with Heliothis virescens caterpillars while the leaves are still moist.
After the desired period, the destruction is determined in %. 100% means that all caterpillars have been killed; 0% means that none of the caterpillars have been killed. The kill figures determined are calculated using Colby's formula.
In this test, a synergistically increased efficacy in comparison with the active compounds when applied individually is shown, for example, by the following active compound combination in accordance with the present application:
TABLE A
plant-injurious insects
Heliothis virescens test
Active compound
Percentage
concentration
destruction
Active compounds
In ppm
after 3 days
Ex. (I-b-1) known
0.32
0
Betacyfluthrin known
0.32
75
Ex. (I-b-1) + betacyfluthrin (1:1)
0.32 + 0.32
found*
calc.**
according to the invention
100
75
*found = found action
**calc. = action calculated using Colby's formula
Example B
Nephotettix Test
solvent:
7 parts by weight of dimethylformamide
emulsifier:
1 part by weight of alkylaryl polyglycol ether
To produce a suitable preparation of active compound, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with emulsifier-containing water to the desired concentration.
Rice seedlings ( Oryza sativa ) are treated by immersion in the active compound preparation of the desired concentration and are populated with green rice leaf-hoppers ( Nephotettix cincticeps ) while the leaves are still moist.
After the desired period, the destruction is determined in %. 100% means that all leafhoppers have been killed; 0% means that none of the leafhoppers have been killed. The kill figures determined form the basis for calculations with Colby's formula.
In this test, a synergistically increased efficacy in comparison with the active compounds when applied individually is shown, for example, by the following active compound combination in accordance with the present application:
TABLE B
plant-injurious insects
Nephotettix test
Active compound
Percentage
concentration
destruction
Active compounds
in ppm
after 6 days
Ex. (I-b-1) known
0.32
0
Betacyfluthrin known
0.32
50
Ex. (I-b-1) + betacyfluthrin (1:1)
0.32 + 0.32
found*
calc.**
according to the invention
85
50
*found = found action
**calc. = action calculated using Colby's formula
Example C
Plutella Test
solvent:
7 parts by weight of dimethylformamide
emulsifier:
1 part by weight of alkylaryl polyglycol ether
To produce a suitable active compound preparation, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with emulsifier-containing water to the desired concentration.
Cabbage leaves ( Brassica oleracea ) are treated by immersion in the active compound preparation of the desired concentration and are populated with diamond-back moth caterpillars ( Plutella xylostella ) while the leaves are still moist.
After the desired period, the destruction is determined in %. 100% means that all caterpillars have been killed; 0% means that none of the caterpillars have been killed. The kill figures determined are calculated using Colby's formula.
In this test, a synergistically increased efficacy in comparison with the active compounds when applied individually is shown, for example, by the following active compound combination in accordance with the present application:
TABLE C
plant-injurious insects
Plutella test
Active compound
Percentage
concentration
destruction
Active compounds
in ppm
after 3 days
Ex. (I-b-1) known
1.6
0
Betacyfluthrin known
1.6
80
Ex. (I-b-1) + betacyfluthrin (1:1)
1.6 + 1.6
found*
calc.**
according to the invention
100
80
*found = found action
**calc. = action calculated using Colby's formula
Example D
Spodoptera exigua Test
solvent:
7 parts by weight of dimethylformamide
emulsifier:
1 part by weight of alkylaryl polyglycol ether
To produce a suitable preparation of active compound, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with emulsifier-containing water to the desired concentration.
Cabbage leaves ( Brassica oleracea ) are treated by immersion in the active compound preparation of the desired concentration and are populated with fall army worm caterpillars ( Spodoptera exigua ) while the leaves are still moist.
After the desired period, the destruction is determined in %. 100% means that all caterpillars have been killed; 0% means that none of the caterpillars have been killed. The kill figures determined are calculated using Colby's formula.
In this test, a synergistically increased efficacy in comparison with the active compounds when applied individually is shown, for example, by the following active compound combination in accordance with the present application:
TABLE D
plant-injurious insects
Spodoptera exigua test
Active compound
Percentage
concentration
destruction
Active compounds
in ppm
after 6 days
Ex. (I-b-1) known
8
0
Betacyfluthrin known
8
90
Ex. (I-b-1) + betacyfluthrin (1:1)
8 + 8
found*
calc.**
according to the invention
100
90
*found = found action
**calc. = action calculated using Colby's formula
Example E
Tetranychus Test
OP-resistant/spray Treatment
solvent:
7 parts by weight of dimethylformamide
emulsifier:
1 part by weight of alkylaryl polyglycol ether
To produce a suitable active compound preparation, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with emulsifier-containing water to the desired concentration.
Bean plants ( Phaseolus vulgaris ) which are severely infested with all stages of the common spider mite ( Tetranychus urticae ) are sprayed with an active compound preparation of the desired concentration.
After the desired period, the action is determined in %. 100% means that all spider mites have been killed; 0% means that none of the spider mites have been killed. The kill figures determined are calculated using Colby's formula.
In this test, a synergistically increased efficacy in comparison with the active compounds when applied individually is shown, for example, by the following active compound combinations in accordance with the present application:
TABLE E
plant-injurious mites
Tetranychus test (OP-resistant/spray treatment)
Active compound
Percentage
concentration
destruction
Active compounds
in ppm
after 14 days
Ex. (I-b-1) known
0.32
0
Methamidophos known
0.32
0
Ex. (I-b-1) + methamidophos (1:1)
0.32 + 0.32
found*
calc.**
according to the invention
90
0
*found = found action
**calc. = action calculated using Colby's formula | The invention relates to novel active compound combinations having very good insecticidal and acaricidal properties and containing
(a) cyclic ketoenols having the formula
in which the groups W, X, Y, Z, A, B, D, and G have the meanings given in the disclosure, and
(b) active compounds listed in the disclosure. | 0 |
FIELD OF THE INVENTION
This invention relates to amphibious vehicles and, more particularly, to a vehicle which is fundamentally developed as an efficient amphibious vehicle rather than constituting an adaptation of a land vehicle to a secondary waterborne mode of operation.
BACKGROUD OF THE INVENTION
Numerous examples of amphibious vehicles are known in the prior art, but virtually all the prior art examples may generally be deemed to be adaptations (often crude and occasionally bizarre) of normally land-bound vehicles (e.g., automobiles, trucks, vans, etc.) to a secondary, water-borne mode of operation. A practically universal problem with the prior art amphibious vehicles has been their poor performance characteristics in the water-borne mode of operation which results from the constraints placed by the need to adapt a vehicle designed only for land-bound operation to the secondary mode of water-borne operation.
In contrast, my amphibious vehicle treats both the land-bound and water-borne modes of operation as of equal importance and has been accordingly developed. As a result, the water-borne mode of operation is highly efficient and admits of high-speed stable traverse through the water when desired.
OBJECTS OF THE INVENTION
It is therefore a broad object of my invention to provide an improved amphibious vehicle.
It is another object of my invention to provide such an amphibious vehicle which is equally well adapted to both land-bound and water-borne modes of operation.
It is still another object of my invention to provide such an amphibious vehicle which, when configured for water-borne operation, is highly efficient during traverse through the water.
In a more specific aspect, it is an object of my invention to provide an amphibious vehicle in which fender/sponson units surrounding each of four wheels may be rotated between alternative positions which, respectively, function as fenders in the land-bound mode of operation and present highly efficient nautical wedges through the water during traverse in the water-borne mode of operation.
SUMMARY OF THE INVENTION
Briefly, these and other objects of my invention are achieved by providing an amphibious vehicle adapted for alternative land and water modes of operation and in which both modes of operation are performned efficiently. The amphibious vehicle includes a vehicle body supported, during land-bound operational, by a front pair of wheels and a rear pair of wheels. Each of the wheels of the vehicle are surrounded by specially-configured fender/sponson units which are rotatable between first and second operational positions through an angle of approximately 180° about the encompassed wheel. In the first operational position, the fender/sponson units function as wheel fenders when the vehicle is configured for land operation. In the second operational position, the fender/sponson units function as sponsons providing floatation to the vehicle and effectively contributing to the streamlined character of the vehicle during traverse through the water by presenting nautical wedges to the water. A rotation mechanism is provided for selectively rotating each of the fender/sponson units between their first and second operational positions.
A drive train is provided to selectively propel the vehicle in the land and water modes of operation. The drive train includes an engine, a drive axle coupling the front wheels to effect a front wheel drive configuration for land-bound operation, a differential disposed intermediate the driven axle, a propeller for propelling the vehicle during water-borne operation, a transfer case having an input and first and second selectable outputs, a shaft coupling the engine to the transfer case input, and drive shaft respectively coupling the transfer case first output to the differential and the second transfer case output to the propeller. A mechanism is also provided for selectively lowering the propeller and a rudder into an operational position during the water-borne mode of operation and for raising the propeller and rudder into a non-operational position during the land-bound mode of operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter of the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, may best be understood by reference to the following description taken in conjunction with the subjoined claims and the accompanying drawing of which:
FIG. 1 is a partially phantom view from the upper left front illustrating one embodiment of my invention configured for the land-bound mode of operation;
FIG. 2 is a view similar to FIG. 1 illustrating the vehicle reconfigured to the water-borne mode of operation;
FIG. 3 is a left side view particularly illustrating certain fender/sponson units, which are a principal component of my vehicle, disposed in a first operational position of the land-bound mode of operation;
FIG. 4 is a view similar to FIG. 3 illustrating the fender/sponson units rotated to a second operational position for the water-borne mode of operation, in which second position, nautical wedges are presented to the water during traverse therethrough;
FIG. 5 is a detail view showing certain of the internal drive train components which include a propeller for propelling the vehicle during the water-borne mode of operation and also illustrating a mechanism for lowering and raising the propeller and its accompanying rudder between operational and non-operational positions;
FIG. 6 is a more detailed fragmentary view of the propeller/rudder mechanism particularly illustrating the manner in which the rudder is actuated;
FIG. 7 is a view taken along the lines 7--7 of FIG. 1 and illustrates details of a coupling unit between the rear pair of fender/sponson units and particularly showing the manner in which they are fixed in place in their two operational positions, a similar tie member being employed to couple the front pair of fender/sponson units;
FIG. 8 is a partially broken away view showing certain of the front wheel drive and fender/sponson element rotation mechanisms;
FIG. 9 is a cross-sectional view taken along the lines 9--9 of FIG. 1 illustrating certain details of the front wheel drive and steering mechanism configured for land-bound operation;
FIG. 10 is a fragmentary exploded view showing the manner in which the fender/sponson units are integrated into the front wheel drive mechanism and also illustrating a variant mechanism for rotating the fender/sponson units; and
FIG. 11 is a detail view showing the sealing relationship between certain componenets illustrated in FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a partially phantom view of an amphibious vehicle 1 according to my invention. In FIG. 1, the vehicle 1 is configured in a first alternative mode particularly adapted for land-bound travel. As a result, a front pair of wheels 2a, 2b and a rear pair of wheels 3a, 3b support the vehicle body above the land surface for conventional land-bound operation. Associated with the front pair of wheels 2a, 2b is a first 4 and second 5 fender/sponson unit. Similarly, a third 6 and fourth 7 fender/sponson unit is associated each with one of the rear pair of wheels 3a, 3b. Thus, the right front wheel 2a is encompassed by the right front fender/sponson unit 4; the left front wheel 2b is encompassed by the left front fender/sponson unit 5; the right rear wheel 3a is encompassed by the third fender/sponson unit 6; and the left rear wheel 3b is encompassed by the fourth fender/sponson unit 7. It will be appreciated from a study of FIG. 1 that the fender/sponson units 4, 5, 6, 7 are performing the traditional function of fenders in a land-bound vehicle.
The two front fender/sponson units 4, 5 are coupled together at their forward edges by a cross member 10 which is fixed in position (and hence fixes the fender/sponson units 4, 5 on position) by a pair of hydraulically-actuated, retractable lock assemblies 11 which are fixed to the vehicle body. When the rams 12 of the lock assemblies 11 are fully extended, as shown in FIG. 1, the cross member 10 is engaged by fingers 13 at the ends of the rams 12 to prevent vertical movement of the cross member 10 with respect to the vehicle body to which the hydraulic lock assemblies are fixed. Similarly, the rear pair of fender/sponson units 6, 7 are connected together by a cross member 15 which is generally rectangular in cross section. Referring briefly also to FIG. 7, downward movement of the cross member 15 (and hence downward movement of the forward ends of the fender/sponson units 6, 7) is limited by the retractable stop 16 carried by the ram 17 of a pair of a hydraulically-actuated lock assembly 18. A second lock assembly is provided as shown in FIG. 1 such that the pair of lock assemblies 18 correspond to the forward pair of lock assemblies 11. As will be discussed further below in conjunction with FIG. 2, a second pair of hydraulically-actuated lock assemblies 20 lock the front pair of fender/sponson units 4, 5 in a seocnd operative position; and similarly, a second pair of hydraulically-actuated lock assemblies 21 constrain the rear pair of fender/sponson units 6, 7 in a second operative position.
For reasons which will become more apparent below the amphibious vehicle 1, when in the land-bound configuration, perfectly a front-wheel drive unit such that a front axle 22 is driven through a differential 23 by an engine-driven shaft 24. As will also become more apparent below, the rear suspension is preferably characterized by a trailing arm arrangement 25 in order to provide sufficient clearance for permitting reconfiguration of the amphibious vehicle 1 into the water-borne mode of operation.
The left side view presented in FIG. 3 corresponds to the vehicle state shown in FIG. 1 and particularly shows the left fender/sponson units 5, 7 performing their fender function when the amphibious vehicle 1 is configured for the land-bound mode of operation. Referring now to FIGS. 2 and 4, the amphibious vehicle 1 is illustrated after it has been reconfigured into a state suitable for undertaking the water-borne mode of operation. It will be appreciated that the fender/sponson units. Whether in the positions shown in FIGS. 1 and 2, or the positions shown in 3 and 4, provide floatation to the vehicle 1 by virtue of the fact that much of their enclosed volumes are water tight in compartments to the front and rear of the wheels 2a, 2b, 3a 3b. The body of the vehicle 1 is also essentially water tight and therefore affords further floatation to the amphibious vehicle 1 when it is immersed in water. When the amphibious vehicle 1 enters the water, it does so in the land-bound configuration illustrated in FIGS. 1 and 3 by simply driving into the water using the front wheel drive to the extent possible. When a sufficient depth has been reached, the fender/sponson units 4, 5, 6, 7 are rotated from their first operational position shown in FIGS. 1 and 3 through an angle of approximately 180° about the wheel encompassed by each to the second operative position illustrated in FIGS. 2 and 4. However, before this reconfiguration can be carried out, it is necessary to retract the hdyraulicallyactuated locking assemblies 11 and 18 to respectively release the cross members 10 and 15. As best shown in FIG. 4, the left side fender/sponson units 5, 7 (and the right side fender/sponson units 4, 6 out of view in FIG. 4) are rotated in the counter-clockwise direction about axes more or less coaxial with the wheels 2b, 3b as indicated by the arrows 26, 27 into the configuration illustrated in FIGS. 2 and 4 which is fixed by the locking action of the hydraulically-actuated locking assemblies 20, 21 engaging the cross members 10, 15. In this position, the leading edge of the fender/sponson unit 4 is nautical wedge 28 which effectively contributes to the streamlined character of the amphibious vehicle during traverse through the water. Similarly, the leading edge of the fender/sponson unit 5, in this configuration, is a nautical wedge, and the fender/sponson units 6, 7 have corresponding forwardly facing nautical wedges 30, 31. Referring again to FIGS. 1 and 3, the nautical wedges 28, 29, 30, 31 effect an aerodynamic trailing edge of the fender/sponson units when they are functioning as wheel fenders.
When it is desired to leave the water and regain the land, the hydraulically actuated locking assemblies 20, 21 are withdrawn to disengage the cross members 20, 15 to permit rotate of the fender/sponson units 4, 5, 6,7 counter-clockwise back to their first operative position. The vehicle is then urged close enough to shore to permit the front wheels to engage the bottom and drive the vehicle onto and over the land. The preference for frontwheel drive will not be understood and arises from the value of this drive configuration for entering and, particularly, leaving the water.
Two alternative versions of the mechanisms of rotating the fender/sponsons units 4, 5, 6, 7 between the two operational positions respectively illustrated in FIGS. 1 and 3 (land-bound) and 2 and 4 (water-borne) will be described in more detail below. In FIGS. 1 and 2, they are represented by motor 32 and outside ring gear 33 (right front) and motor 34 and outside ring gear 35 (right rear).
The amphibious vehicle of the present invention preferably uses the same power source for both land-bound and water-borne operation. Thus, referring to FIG. 8, rotational power from an engine/transmission unit 40 is conveyed via shaft 41 to the input of a transfer case 42. Transfer case 42 may be typical of conventional units used with four-wheel drive vehicles and thus has first and second output facing, respectively, forwardly and rearwardly, as shown in FIG. 8. The first output shaft 43 of transfer case 42 is coupled, via a pair of U-joints 44, 45 and an intermediate shaft 46, to the differential 23 which provides front wheel drive to the fornt wheel axle 22 in the more or less conventional fashion. Referring to both FIGS. 5 and 8, the second output shaft 47 from transfer case 42 is connected, via a U-joint 48, to a rearwardly-directed shaft 49 which terminates at a rear most position with a propeller 50.
As best shown in FIG. 5, the propeller 50 has a lowered, operational position for water-borne use and an alernative, raised, non-operational position for land-bound use. The manner in which the propeller 50, along with a rudder 51 and its accompanying mechanisms, is moved between its alternative positions may best be appreciated with reference to FIGS. 5 and 6. The propeller 50 is supported from a pivotal platform 52 by a bracket 53 which carries, at its lower end, a bearing structure 54 through which the shaft 49 passes immediately forward of the propeller 50. At the rear of the pivotal platform 52, the rudder 51 includes a rudder post 55 which extends upwardly through a journal 56 through the pivotal platform 52.
The pivotal platform 52 swings about a horizontal axis 60 (fixed to the vehicle body by any convenient means) disposed toward the front edge of the platform between the two alternative positions illustrated in FIG. 5. The vertical position of the pivotal 52 is controlled by a hydraulic cylinder 61 having its ram 26 pivotally attached to the platform 52 as shown at 63. Therefore, it will be understood that when the ram 62 of the hydraulic cylinder 61 is in its fully extended position, the pivotal platform 52, the propeller 50 and the rudder 51 are all lowered into their operational position as indicated by the sold lines in FIG. 5 and in FIG. 6. Alternatively, for the land-bound mode of operation, the pivotal platform 52, bringing with it the rudder 51 and the propeller 50, is raised to the non-operational position by retraction of the ram 62 of the hydraulic cylinder 61. Referring briefly to FIGS. 1 and 2, it will again be noted that the trailing arm type of rear suspension 25 is favored in order to give adequate clearance for the retractable mechanism just described.
The position of rudder 51 is controlled by a steering arm 65 acting through the rudder post 55 as best shown in FIG. 6. Cable 66 passing through guide 67 supported on pivotal platform 52 may be moved forwardly and rearwardly to correspondingly move the steering arm 6 and hence the rudder post 55 and the rudder itself 51 to provide steering while in the water-borne traversing mode of operation. Steering may be effected from the same steering wheel used to steer on land by appropriately coupling the mechanisms.
FIG. 9 shows further details of the steering mechanism for the front wheels and also illustrates a presently preferred drive arrangement of the fender/sponson units to effect their rotation about their respectively encompassed wheels. The steering box 70 has an input from a steering shaft 71, rotation of which (by a steering wheel, not shown) causes lateral movement of the steering arms 72, 73 which respectively connect at their outboard ends taking pin assemblies 74, 75 to move the front wheels 2a, 2b from side to side to effect steering in the more or less conventional manner. The width of the fender/sponson units in the wheel housing area is selected to provide adequate clearance for the tires during the steering operation.
It will be noted that, in FIG. 9, the motor and ring gear assemblies are different from those illustrated in FIGS. 1, 2 and 8. FIGS. 9, 10 and 11 illustrate the presently preferred method for coupling the fender/sponson units 4, 5, 6, 7 to the amphibious vehicle body, to effect their rotation and to provide effective engine compartment sealing when the amphibious vehicle 1 is configured for water-borne operation. As best shown in the exploded view of FIG. 10, the left front sponson 5 carries an integral ring member 80 which has inwardly directed teeth 81 disposed about its periphery adjacent the side of the sponson directed toward the vehicle body. When the fender/sponson unit 5 is assembled to the vehicle, the ring member 80 fits over the fender/sponson suport ring 82 with rotatable clearance. A drive motor 83 (which may be electric or hydraulic) is carried on the support ring and has a shaft with gear teeth 84 extending through an aperture 85 in the support ring to engage the internal teeth 81 of the integral ring member 80. Thus, when the fender/sponson unit is to be repositioned and has been unlocked, energization of the motor 83 will cause its rotation about an axis at the center of the integral ring member 80. Motor 83 may be electrically energized or, preferably, hydraulically energized.
FIGS. 10 and 11, in particular, show effective means for integrating the fender/sponson unit to the vehicle body and for preventing wear from entering the engine compartment when the amphibious vehicle is configured for waterborne operation. A fender/sponson unit retainer plate 88 bolts to the fender/sponson unit support ring 82 after the fender/sponson unit 5 has been placed in position with the integral ring member 80 peripherally overlaying the support ring 82. The fender/sponson unit retainer plate 88 is generally in the form of a flat-bottomed "V" and includes a peripheral flange region 89 extending along the sides and bottom, but not the top, of the "V". On the inside face of the peripheral flange region 89, a rubber seal 90 extends continuously. An axle flange plate 92, also in the form of a flat-bottomed "V", bolts to an axle flange 93 which is affixed to the axle housing 94 by, for example, welding. Thus, it will be understood that the axle flange plate 92 moves vertically with the wheels whereas the fender/sponson unit retainer plate 88 moves vertically with the fender/sponson unit 5. Note that flange 93 is not attached to support ring 52; axle 94 runs freely through support ring 52.
As a result of this arrangement, the axle flange plate 92 remains above the seal 90 as long as the weight of the amphibious vehicle is placed on the wheels during land-bound operation. However, when the vehicle is driven into the water and begins to float, the fender/sponson unit 5 moves upwardly (because of its flotation) carrying the retainer plate 88 with it until the edges of the axle flange plate 92 engage the rubber seal 90 to thereby prevent water from entering the engine compartment. For the front wheels, the axle flange plate 92 includes an aperture 95 through which the steering arms 72, 73 (FIG. 9) may pass. For the rear wheels, no corresponding aperture is necessary.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. For example, a vehicle having only three wheels (or more than four wheels) could be constructed with a like number of fender/sponson units. Having fully described and disclosed in the instant invention in such clear and concise terms as to enable those skilled in the art to understand and practice the same, the invention claimed is: | An amphibious vehicle is disclosed which is adapted for alternative land and water modes of operation and in which both modes of operation are performed efficiently. The amphibious vehicle includes a vehicle body supported, during land-bound operation, by a front pair of wheels and a rear pair of wheels. Each of the wheels of the vehicle are surrounded by specially-configured fender/sponson units which are rotatable between first and second operational positions through an angle of approximately 180° about the encompassed wheel. In the first operational position, the fender/sponson units function as wheel tenders for land operation. In the second operational position, the fender/sponson units function as sponsons providing floatation to the vehicle and effectively contributing to the streamlined character of the vehicle during traverse through the water by presenting nautical wedges to the water. A rotation mechanism is provided for selectively rotating each of the fender/sponson units between their first and second operational positions. A drive train is provided to selectively propel the vehicle in the land and water modes of operation. The drive train includes a front wheel drive configuration for land-bound operation and a propeller for propelling the vehicle during water-borne operation. A transfer case directs the drive to either the front wheels or the propeller which can be selectively lowered, along with a rudder, for water-borne operation. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2008-209121 filed on Aug. 15, 2008, the entire contents of which are incorporated herein by reference.
FIELD
An aspect of the embodiments discussed herein is directed to a semiconductor device having a multilayer interconnection structure.
BACKGROUND
In current semiconductor integrated circuit devices, a multilayer interconnection structure has been used to interconnect among semiconductor elements. In ultrafine and ultra high-speed semiconductor devices, in order to reduce the problem of signal delay (RC delay), a low-resistance copper (Cu) pattern is used as a wiring pattern.
In order to form a cupper wire, a so-called damascene method or dual-damascene method has been used. The damascene method is a method of forming a wire in which a Cu layer is buried in a wire groove or a via hole formed in an interlayer insulating layer using chemical mechanical polishing (CMP).
When the Cu wire is formed, a diffusion-reducing barrier is formed to reduce the diffusion of Cu atoms into an interlayer insulating layer. For the diffusion-reducing barrier, in general, refractory metals, such as tantalum (Ta), titanium (Ti), and tungsten (W), and conductive nitrides of the above refractory metals have been used.
However, the above materials have a higher resistivity than that of Cu; hence, in order to further decrease the wiring resistance, the thickness of the diffusion-reducing barrier may be decreased as small as possible. Accordingly, Japanese Laid-open Patent Publication No. 2007-59660 discusses a technique that a Cu—Mn alloy is used instead of the diffusion-reducing barrier. The reason for this is that MnSi x O y is formed in a self-alignment manner at the interface between an interlayer insulating layer and a Cu wire by a reaction of Mn with O 2 and Si, which are contained in the interlayer insulating layer, and that Mn oxides function as a diffusion-reducing layer. However, at the interface between the interlayer insulating layer and the Cu wire, when Mn which is not allowed to react with O 2 contained in the interlayer insulating layer dissolves in the Cu wire, the resistance of the Cu wire may increase.
SUMMARY
According to an aspect of an embodiment, a semiconductor device includes an insulating layer formed over a semiconductor substrate, the insulating layer including oxygen, a first wire formed in the insulating layer, and a second wire formed in the insulating layer over the first wire and containing manganese, oxygen, and copper, the second wire having a projection portion formed in the insulating layer and extending downwardly but spaced apart from the first wire.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plan view illustrating the structure of a semiconductor device 50 a according to a first embodiment;
FIG. 1B is a cross-sectional view of the semiconductor device 50 a taken along the line X-Y illustrated in FIG. 1A ;
FIGS. 2A-2B are views each illustrating a method of manufacturing the semiconductor device 50 a according to the first embodiment;
FIGS. 3A-3B are views each illustrating the method of manufacturing the semiconductor device 50 a according to the first embodiment;
FIGS. 4A-4B are views each illustrating the method of manufacturing the semiconductor device 50 a according to the first embodiment;
FIGS. 5A-5B are views each illustrating the method of manufacturing the semiconductor device 50 a according to the first embodiment;
FIG. 6A is a plan view illustrating the structure of a semiconductor device 50 b according to a second embodiment;
FIG. 6B is a cross-sectional view of the semiconductor device 50 b taken along the line X-Y illustrated in FIG. 6A ;
FIG. 7A is a plan view illustrating the structure of a semiconductor device 50 c according to a third embodiment; and
FIG. 7B is a cross-sectional view of the semiconductor device 50 c taken along the line X-Y illustrated in FIG. 7A .
DESCRIPTION OF EMBODIMENTS
Hereinafter, a first embodiment, a second embodiment, and a third embodiment will be described. However, the present technique is not limited to the embodiments mentioned above.
In the first embodiment, FIGS. 1A to 6B are views illustrating a semiconductor device 50 a and a method of manufacturing the same in detail.
According to the structure of the semiconductor device 50 a of the first embodiment and to the method of manufacturing the same, a contact area between an insulating layer containing oxygen and a second barrier layer containing Mn may be increased. Hence, Mn may be sufficiently consumed by the formation of Mn oxides at a portion at which the contact area between the insulating layer and the second barrier layer is increased, and an increase in resistance of a copper wire may be reduced.
FIGS. 1A and 1B each illustrate the structure of the semiconductor device 50 a of the first embodiment. FIG. 1A is a plan view of the semiconductor device 50 a . FIG. 1B is a cross-sectional view taken along the line X-Y illustrated in FIG. 1A .
In the semiconductor device 50 a of the first embodiment illustrated in FIG. 1A , a fourth interlayer insulating layer is represented by reference numeral 15 b , second wires (Cu wire) are each represented by reference numeral 19 b , and a third wire is represented by reference numeral 19 c . The fourth interlayer insulating layer 15 b is formed so as to cover an n-type MOS transistor forming region 30 a and a p-type MOS transistor forming region 30 b . The fourth interlayer insulating layer 15 b is preferably formed of SiO 2 . As a material forming the interlayer insulating layer 15 b , a material is preferably used which has a higher resistance against chemical mechanical polishing (CMP) than that of a third interlayer insulating layer 14 b which will be described later.
The second wires 19 b are formed so as to be partly overlapped with the n-type MOS transistor forming the region 30 a and the p-type MOS transistor forming the region 30 b . The second wires 19 b each have an approximately rectangular shape or an approximately circular shape. The second wires 19 b are each preferably formed so as to be electrically connected to the n-type MOS transistor forming the region 30 a and the p-type MOS transistor forming the region 30 b . The second wires 19 b are preferably formed of copper (Cu) which has a low resistivity.
The third wire 19 c is formed in the vicinity of the p-type MOS transistor forming the region 30 b . The third wire 19 c has an approximately rectangular shape. The third wire 19 c is not electrically connected to the n-type MOS transistor forming the region 30 a and the p-type MOS transistor forming the region 30 b . The third wire 19 c is preferably formed of Cu which has a low resistivity.
In FIG. 1B , the semiconductor device 50 a according to the first embodiment includes a transistor forming layer 60 and a multilayer interconnection structure 40 a . The transistor forming layer 60 has the n-type MOS transistor forming the region 30 a and the p-type MOS transistor forming the region 30 b . The multilayer interconnection structure 40 a has first wires 19 a , the second wires 19 b , and the third wire 19 c . In addition, in FIG. 1B , constituents similar to those described with reference to FIG. 1A are designated by the same reference numerals.
As illustrated in FIG. 1B , a silicon substrate 1 has an n-type conductivity. An element isolation region 2 has a shallow trench isolation structure. The n-type MOS transistor forming region 30 a and the p-type MOS transistor forming region 30 b are defined by the element isolation region 2 .
In the n-type MOS transistor forming region 30 a , a p-type well region is represented by reference numeral 3 a , a gate insulating film is represented by reference numeral 4 a , a gate electrode is represented by reference numeral 5 a , a source region is represented by reference numeral 7 a , a drain region is represented by reference numeral 8 a , and a silicide layer is represented by reference numeral 9 a.
The p-type well region 3 a is formed by performing ion-implantation of a p-type impurity in the silicon substrate 1 . The gate insulating film 4 a is formed on the silicon substrate 1 in the p-type well region 3 a . The gate electrode 5 a is formed on the silicon substrate 1 with the gate insulating film 4 a interposed therebetween. Sidewalls 6 a are formed on side walls of the gate electrode 5 a . The sidewalls 6 a may be formed using silicon oxide (SiO 2 ) which is an insulating material. The source region 7 a and the drain region 8 a are formed in the p-type well region 3 a of the silicon substrate 1 . The silicide layers 9 a are provided on the gate electrode 5 a and in the surface of the silicon substrate 1 in the source region 7 a and the drain region 8 a.
In the p-type MOS transistor forming region 30 b , an n-type well region is represented by reference numeral 3 b , a gate insulating film is represented by reference numeral 4 b , a gate electrode is represented by reference numeral 5 b , a source region is represented by reference numeral 7 b , a drain region is represented by reference numeral 8 b , and a silicide layer is represented by reference numeral 9 b.
The n-type well region 3 b is formed by performing ion-implantation of an n-type impurity in the silicon substrate 1 . The gate oxide film 4 b is formed on the silicon substrate 1 in the n-type well region 3 b . The gate electrode 5 b is formed on the silicon substrate 1 with the gate oxide film 4 b interposed therebetween. Sidewalls 6 b are formed on side walls of the gate electrode 5 b . The sidewalls 6 b may be formed using silicon oxide (SiO 2 ) which is an insulating material. The source region 7 b and the drain region 8 b are formed in the n-type well region 3 b of the silicon substrate 1 . The silicide layers 9 b are provided on the gate electrode 5 b and in the surface of the silicon substrate 1 in the source region 7 b and the drain region 8 b.
A protective layer 11 is formed so as to cover the silicon substrate 1 , that is, so as to cover the n-type MOS transistor forming region 30 a and the p-type MOS transistor forming region 30 b on the silicon substrate 1 . The protective layer 11 is preferably formed, for example, of silicon nitride (SiN). The protective layer 11 is formed to protect the n-type MOS transistor forming region 30 a and the p-type MOS transistor forming region 30 b.
A first interlayer insulating layer 12 is formed on the protective layer 11 . The first interlayer insulating layer 12 is preferably formed, for example, of silicon oxide (SiO 2 ). The first interlayer insulating layer 12 is formed to ensure the insulation between the n-type MOS transistor forming region 30 a and the p-type MOS transistor forming region 30 b.
Openings 24 a are formed to penetrate the protective layer 11 and the first interlayer insulating layer 12 so that conductive materials to be filled in the openings 24 a are electrically connected to the gate electrode 5 a , the source region 7 a , and the drain region 8 a of the n-type MOS transistor forming region 30 a . Openings 24 b are formed to penetrate the protective layer 11 and the first interlayer insulating layer 12 so that conductive materials to be filled in the openings 24 b are electrically connected to the gate electrode 5 b , the source region 7 b , and the drain region 8 b of the p-type MOS transistor forming region 30 b.
A wire 10 a is formed by burying a conductive material in each opening 24 a . A wire 10 b is formed by burying a conductive material in each opening 24 b . The conductive materials are each preferably formed, for example, of copper (Cu). In addition, the wire 10 a and the corresponding opening 24 a are collectively called a contact via, and the wire 10 b and the corresponding opening 24 b are also collectively called a contact via.
In the multilayer interconnection structure 40 a , a second interlayer insulating layer is represented by reference numeral 13 a , a third interlayer insulating layer is represented by reference numeral 14 a , a fourth interlayer insulating layer is represented by reference numeral 15 a , a second interlayer insulating layer is represented by reference numeral 13 b , a third interlayer insulating layer is represented by reference numeral 14 b , a fourth interlayer insulating layer is represented by reference numeral 15 b , a first barrier layer is represented by reference numeral 16 a , a second barrier layer is represented by reference numeral 17 a , a conductive layer is represented by reference numeral 18 a , the first wire is represented by reference numeral 19 a , a first barrier layer is represented by reference numeral 16 b , a second barrier layer is represented by reference numeral 17 b , a conductive layer is represented by reference numeral 18 b , the second wire is represented by reference numeral 19 b , a first barrier layer is represented by reference numeral 16 c , a second barrier layer is represented by reference numeral 17 c , a conductive layer is represented by reference numeral 18 c , the third wire is represented by reference numeral 19 c , a dummy plug is represented by reference numeral 20 c , and openings are represented by reference numerals 21 a , 21 b , and 21 c.
The second interlayer insulating layer 13 a is formed on the first interlayer insulating layer 12 . The second interlayer insulating layer 13 a is preferably formed, for example, of silicon carbide (SiC). The second interlayer insulating layer 13 a preferably has a thickness of 15 nm to 30 nm. The second interlayer insulating layer 13 a functions as an etching stopper when the openings 21 a , which will be described later, are formed.
The third interlayer insulating layer 14 a is formed on the second interlayer insulating layer 13 a . The third interlayer insulating layer 14 a is preferably formed, for example, of a low dielectric-constant material having a relative dielectric constant of 3.2 or less. As the low dielectric-constant material, for example, methylated-hydrogen silsesquoxane (MSQ) having a relative dielectric constant of 2.6, SiLK K or porous SiLK K, which are the registered trade names of Dow Chemical Company, a hydrocarbon-based polymer, or carbon-containing SiO 2 (SiOC) may be preferably used. The third interlayer insulating layer 14 a is used to reduce the problem of signal delay (RC delay) in the multilayer interconnection structure. The third interlayer insulating layer 14 a preferably has a thickness of 100 nm to 300 nm.
The fourth interlayer insulating layer 15 a is formed on the third interlayer insulating layer 14 a . The fourth interlayer insulating layer 15 a is preferably formed, for example, of SiO 2 . The fourth interlayer insulating layer 15 a functions as a protective layer for the third interlayer insulating layer 14 a having a low resistance against chemical mechanical polishing (CMP). The fourth interlayer insulating layer 15 a preferably has a thickness of 15 nm to 30 nm.
The openings 21 a are formed to penetrate the second interlayer insulating layer 13 a , the third interlayer insulating layer 14 a , and the fourth interlayer insulating layer 15 a so that conductive materials to be filled in the openings 21 a are electrically connected to the respective wires 10 a . The first wire 19 a is formed of the conductive layer 18 a buried in the opening 21 a . The conductive layer 18 a is preferably formed, for example, of copper (Cu).
The first barrier layer 16 a and the second barrier layer 17 a are sequentially provided between the opening 21 a and the conductive layer 18 a . The first barrier layer 16 a is formed at the opening 21 a side. The second barrier layer 17 a is formed at the conductive layer 18 a side.
Since the Cu wire is formed in the opening 21 a , a material which reduces Cu diffusion and which has superior adhesion to Cu is used for the first barrier layer 16 a . As the material described above, for example, titanium (Ti), titanium nitride (TiN), titanium silicide nitride (TiSiN), tungsten (W), tungsten nitride (WN), tantalum (Ta), or tantalum nitride (TaN) may be used. In addition, the first barrier layer 16 a may be formed using a laminate including at least two layers of the above materials. The first barrier layer 16 a preferably has a thickness of 3 nm to 10 nm. Incidentally, the first barrier layer 16 a may only be formed when it is necessary.
The second barrier layer 17 a is formed between the first barrier layer 16 a and the conductive layer 18 a . Since the third interlayer insulating layer 14 a is formed of SiOC, the fourth interlayer insulating layer 15 a is formed of SiO 2 , and Mn also reacts with Si, the composition of Mn-containing oxides forming the second barrier layer 17 a is represented by Mn x Si y O z (x:y:z is in the range of 1:1:3 to 1:3:5). In addition, the second barrier layer 17 a preferably has a thickness of 1 nm to 5 nm.
The second interlayer insulating layer 13 b is formed on the fourth interlayer insulating layer 15 a . The second interlayer insulating layer 13 b is preferably formed, for example, of silicon carbide (SiC) as with the second interlayer insulating layer 13 a . The second interlayer insulating layer 13 b preferably has a thickness of 15 nm to 30 nm.
The third interlayer insulating layer 14 b is formed on the second interlayer insulating layer 13 b . As with the third interlayer insulating layer 14 a , the third interlayer insulating layer 14 b is preferably formed, for example, of a low dielectric-constant material having a relative dielectric constant of 3.2 or less. The third interlayer insulating layer 14 b preferably has a thickness of 100 nm to 300 nm.
The fourth interlayer insulating layer 15 b is formed on the third interlayer insulating layer 14 b . As with the fourth interlayer insulating layer 15 a , the fourth interlayer insulating layer 15 b is preferably formed, for example, of SiO 2 . The fourth interlayer insulating layer 15 b functions as a protective layer for the third interlayer insulating layer 14 b having a low CMP resistance. The fourth interlayer insulating layer 15 b preferably has a thickness of 15 nm to 30 nm.
The openings 21 b are formed to penetrate the second interlayer insulating layer 13 b , the third interlayer insulating layer 14 b , and the fourth interlayer insulating layer 15 b so that conductive materials to be filled in the openings 21 b are electrically connected to the respective first wires 19 a . The second wire 19 b is formed of the conductive layer 18 b buried in the opening 21 b . The conductive layer 18 b is preferably formed, for example, of copper (Cu).
The first barrier layer 16 b and the second barrier layer 17 b are sequentially provided between the opening 21 b and the conductive layer 18 b . The first barrier layer 16 b is formed at the opening 21 b side. The second barrier layer 17 b is formed at the conductive layer 18 b side.
Since the Cu wire is formed in the opening 21 b as with the first barrier layer 16 a , a material which reduces Cu diffusion and which has superior adhesion to Cu is used for the first barrier layer 16 b . The first barrier layer 16 b preferably has a thickness of 3 nm to 10 nm. Incidentally, the first barrier layer 16 b may only be formed when it is necessary.
As with the second barrier layer 17 a , the second barrier layer 17 b is formed between the first barrier layer 16 b and the conductive layer 18 b . Since the third interlayer insulating layer 14 b is formed of SiOC, the fourth interlayer insulating layer 15 b is formed of SiO 2 , and Mn also reacts with Si, the composition of Mn-containing oxides forming the second barrier layer 17 b is represented by Mn x Si y O z (x:y:z is in the range of 1:1:3 to 1:3:5). In addition, the second barrier layer 17 b preferably has a thickness of 1 nm to 5 nm.
The opening 21 c is formed to penetrate the second interlayer insulating layer 13 b , the third interlayer insulating layer 14 b , and the fourth interlayer insulating layer 15 b . Unlike the opening 21 b , a conductive material to be filled in the opening 21 c is not electrically connected to the first wire 19 a . The third wire 19 c is formed by burying the conductive layer 18 c in the opening 21 c . The conductive layer 18 c is preferably formed, for example, of copper (Cu).
The dummy plug 20 c is formed in a lower part of the opening 21 c . The dummy plug 20 c has, for example, a cylindrical shape and is formed to have a width smaller than that of the opening 21 c . The dummy plug 20 c is formed to increase formation areas of the second interlayer insulating layer 13 b , the third interlayer insulating layer 14 b , the conductive layer 18 c , and the second barrier layer 17 c . Accordingly, at a portion at which the contact area of the third wire 19 c with the second interlayer insulating layer 13 b and the third interlayer insulating layer 14 b is increased, Mn may be sufficiently consumed by the formation of Mn oxides. Hence, the resistance of the Cu wire may be maintained at a low level.
In addition, although the resistivity of Cu is 1.55 Ω·cm, the resistivity of Mn is 136 Ω·cm. Hence, it is understood that the resistivity of Mn is significantly larger than that of Cu. Accordingly, when Mn is not sufficiently consumed between the third wire 19 c and the third and fourth interlayer insulating layers 14 b and 15 b , and when Mn dissolves in the Cu wire, the resistance of the Cu wire disadvantageously increases.
The first barrier layer 16 c and the second barrier layer 17 c are sequentially provided between the opening 21 c and the conductive layer 18 c . The first barrier layer 16 c is formed at the opening 21 c side. The second barrier layer 17 c is formed at the conductive layer 18 c side.
Since the Cu wire is formed in the opening 21 c , a material which reduces Cu diffusion and which has superior adhesion to Cu is used for the first barrier layer 16 c as with the first barrier layer 16 b . The first barrier layer 16 c preferably has a thickness of 3 nm to 10 nm. Incidentally, the first barrier layer 16 c may only be formed when it is necessary.
As with the second barrier layer 17 b , the second barrier layer 17 c is formed between the first barrier layer 16 c and the conductive layer 18 c . Since the third interlayer insulating layer 14 b is formed of SiOC, the fourth interlayer insulating layer 15 b is formed of SiO 2 , and Mn also reacts with Si, the composition of Mn-containing oxides forming the second barrier layer 17 c is represented by Mn x Si y O z (x:y:z is in the range of 1:1:3 to 1:3:5). In addition, the second barrier layer 17 c preferably has a thickness of 1 nm to 5 nm.
FIGS. 2A to 5B are views illustrating a method of manufacturing the semiconductor device 50 a according to the first embodiment.
FIG. 2A is a view illustrating the state in which a part of the multilayer interconnection structure 40 a is formed on the transistor forming layer 60 illustrated in FIG. 1B .
First, on the first interlayer insulating layer 12 (not illustrated in FIG. 2A ) of the transistor forming layer 60 , the second interlayer insulating layer 13 a composed, for example, of SiC having a thickness of 15 nm to 30 nm is formed by a chemical vapor deposition (CVD) method or the like. The first interlayer insulating layer 12 functions as an etching stopper when the openings 21 a are formed which will be described later.
Next, the third interlayer insulating layer 14 a composed, for example, of SiOC having a thickness of 100 nm to 300 nm is formed on the second interlayer insulating layer 13 a . The fourth interlayer insulating layer 15 a is formed using a silane gas (such as trimethylsilane), for example, by a plasma chemical vapor deposition (CVD) method. The third interlayer insulating layer 14 a is preferably formed, for example, from a low dielectric constant material having a relative dielectric constant of 3.2 or less.
Subsequently, on the third interlayer insulating layer 14 a , the fourth interlayer insulating layer 15 a is formed, for example, from SiO 2 having a thickness of 15 nm to 30 nm. The fourth interlayer insulating layer 15 a is formed using a silane gas (such as SiH 2 Cl 2 , SiH 4 , Si 2 H 4 , or Si 2 H 6 ) by a CVD method or the like. The fourth interlayer insulating layer 15 a functions as a protective layer for the third interlayer insulating layer 14 a having a low CMP resistance.
Next, by a lithography operation and an etching operation, the openings 21 a are formed which penetrate the fourth interlayer insulating layer 15 a , the third interlayer insulating layer 14 a , and the second interlayer insulating layer 13 a and which communicate with the wires 10 a and 10 b (not illustrated in FIG. 2A ). The fourth interlayer insulating layer 15 a is etched, for example, by a reactive ion etching (RIE) method using a C 4 F 6 /Ar/O 2 mixed gas including C 4 F 6 which is a fluorine-containing gas. The third interlayer insulating layer 14 a is etched, for example, by an RIE method. The second interlayer insulating layer 13 a is etched, for example, by an RIE method using a CH 2 F 2 /N 2 /O 2 mixed gas including CH 2 F 2 which is a fluorine-containing gas. For this etching, the chamber temperature is set to room temperature or the like, and the gas flow rates are set, for example, to 10 to 35 sccm for CH 2 F 2 , 50 to 100 sccm for N 2 , and 15 to 40 sccm for O 2 .
Subsequently, for example, by a physical vapor deposition (PVD) method, such as a sputtering method, the first barrier layer 16 a composed, for example, of Ta having a thickness of 2 nm to 5 nm is formed. Since the Cu wire is formed in the opening 21 a , a material which reduces Cu diffusion and which has superior adhesion to Cu is used for the first barrier layer 16 a . Incidentally, the first barrier layer 16 a may only be formed when it is necessary.
Next, a CuMn alloy layer (not illustrated) composed, for example, of an alloy of Cu and manganese (Mn) having a thickness of 5 nm to 30 nm is formed so as to cover an inside wall of the opening 21 a provided with the first barrier layer 16 a . The CuMn alloy layer contains 0.2 to 1.0 atomic percent of Mn atoms and preferably contains 0.5 atomic percent or less thereof. Besides the CuMn alloy layer, a layer composed of a mixture containing Mn in Cu may also be used. In addition, when the CuMn alloy layer reacts, the second barrier layer 17 a which will be described later is formed, and hence the CuMn alloy layer may not be illustrated in FIG. 2A . However, in a manufacturing process which will be described later, the CuMn alloy layer is illustrated.
Next, in a subsequent operation, by a heat treatment performed after the conductive layer 18 a is buried in the opening 21 a , before Cu is diffused to the second interlayer insulating layer 13 a , the third interlayer insulating layer 14 a , and the fourth interlayer insulating layer 15 a , which are exposed to the side wall of the opening 21 a , Mn is diffused to the second interlayer insulating layer 13 a , the third interlayer insulating layer 14 a , and the fourth interlayer insulating layer 15 a . In addition, since Mn is allowed to react with oxygen contained in the third interlayer insulating layer 14 a and the fourth interlayer insulating layer 15 a , the second barrier layer 17 a composed of Mn-containing oxides is formed.
In the operation described above, although Mn is used as a metal material forming the alloy layer other than Cu, when a metal material is available which has a higher diffusion rate in Cu that that of Cu, and whose oxide has a Cu diffusion-reducing effect and superior adhesion to Cu, the above metal material may also be used as well as Mn. As the metal material described above, for example, besides Mn, niobium (Nb), zirconium (Zr), chromium (Cr), vanadium (V), yttrium (Y), technetium (Tc), or rhenium (Re) may be mentioned.
Since the CuMn alloy layer also functions as a seed layer of electrolytic plating, the thickness thereof is controlled to an appropriate value to form a buried wire in accordance with the wire dimension. In this embodiment, a CuMn alloy layer having a thickness, for example, of 5 nm to 30 nm is formed.
In this operation, the second barrier layer 17 a is formed so as to cover the side wall of the opening 21 a . However, since Mn in the second barrier layer 17 a is diffused by a subsequent heat treatment and is allowed to react with oxygen in the third interlayer insulating layer 14 a and the fourth interlayer insulating layer 15 a , a CuMn alloy layer including Mn-containing oxides is formed; hence, the CuMn alloy layer covering the inside wall of the opening 21 a may not have a uniform thickness.
Next, by an electrolytic plating method, the conductive layer 18 a composed of Cu having a thickness of 0.5 μm to 2.0 μm is deposited so as to be buried in the opening 21 a . In this embodiment, although the conductive layer 18 a composed of Cu is formed, the conductive layer 18 a may be an alloy layer composed of Cu and a metal other than Cu, and as the metal other than Cu, a material is used which does not increase the resistance of a wire even when it is contained in Cu.
Subsequently, a heat treatment is performed at 100 to 250° C. for 1 to 60 minutes. By this heat treatment, Mn is diffused from the CuMn alloy layer and is allowed to react with oxygen contained in the third interlayer insulating layer 14 a and the fourth interlayer insulating layer 15 a exposed to the side wall of the opening 21 a . In addition, the second barrier layer 17 a composed of Mn-containing oxides is formed to have a thickness of 1 nm to 5 nm on the side wall of the opening 21 a provided with the first barrier layer 16 a.
Next, for example, by a CMP method, the first barrier layer 16 a , the second barrier layer 17 a , and the conductive layer 18 a are partly removed approximately to the middle of the fourth interlayer insulating layer 15 a by polishing, so that the first wire 19 a composed of Cu is formed in the opening 21 a.
FIG. 2B is a view illustrating the state in which the second interlayer insulating layer 13 b , the third interlayer insulating layer 14 b , and the fourth interlayer insulating layer 15 b are sequentially formed in that order on the fourth interlayer insulating layer 15 a.
First, as in the case illustrated in FIG. 2A , the second interlayer insulating layer 13 b composed, for example, of SiC having a thickness of 15 nm to 30 nm is formed on the fourth interlayer insulating layer 15 a (not illustrated in the figure) by a CVD method or the like. The fourth interlayer insulating layer 15 a functions as an etching stopper when the openings 21 b and 21 c are formed which will be described later.
Subsequently, as in the case illustrated in FIG. 2A , the third interlayer insulating layer 14 b composed, for example, of SiOC having a thickness of 100 nm to 300 nm is formed on the second interlayer insulating layer 13 b by a plasma CVD method or the like.
Next, the fourth interlayer insulating layer 15 b composed, for example, of SiO 2 having a thickness of 15 nm to 30 nm is formed on the third interlayer insulating layer 14 b by a CVD method or the like.
FIG. 3A is a view illustrating the state in which openings 21 g are formed by a lithography operation and an etching operation which penetrate the fourth interlayer insulating layer 15 b and which each have a grooved shape in the third interlayer insulating layer 14 b.
As in the case illustrated in FIG. 2A , the fourth interlayer insulating layer 15 b is etched, for example, by an RIE method using a C 4 F 6 /Ar/O 2 mixed gas including C 4 F 6 which is a fluorine-containing gas.
As in the case illustrated in FIG. 2A , the third interlayer insulating layer 14 b is etched, for example, by an RIE method. By these etching operations, the openings 21 g are formed which penetrate the fourth interlayer insulating layer 15 b and which each have a grooved shape in the third interlayer insulating layer 14 b.
FIG. 3B is a view illustrating the state in which the openings 21 b and 21 c are formed by a lithography operation and an etching operation which penetrate the fourth interlayer insulating layer 15 b and which each have a via shape in the third interlayer insulating layer 14 b.
As in the case illustrated in FIG. 2A , the fourth interlayer insulating layer 15 b is etched, for example, by an RIE method using a C 4 F 6 /Ar/O 2 mixed gas including C 4 F 6 which is a fluorine-containing gas.
As in the case illustrated in FIG. 2A , the third interlayer insulating layer 14 b is etched, for example, by an RIE method. By this etching operation, the third interlayer insulating layer 14 b located under the openings 21 g is etched. By this etching operation, the second interlayer insulating layer 13 b is exposed at the bottom of the openings 21 b and 21 c.
The second interlayer insulating layer 13 b is etched, for example, by an RIE method using a CH 2 F 2 /N 2 /O 2 mixed gas including CH 2 F 2 which is a fluorine-containing gas. For this etching, the chamber temperature is set to room temperature or the like, and the gas flow rates are set, for example, to 10 to 35 sccm for CH 2 F 2 , 50 to 100 sccm for N 2 , and 15 to 40 sccm for O 2 . By this etching operation, the via-shaped openings 21 b and 21 c are formed in the third interlayer insulating layer 14 b and the second interlayer insulating layer 13 b.
The opening 21 b is formed so that a conductive material to be filled in the opening 21 b is electrically connected to the first wire 19 a . On the other hand, the opening 21 c is formed on the fourth interlayer insulating layer 15 a under which the first wire 19 a is not provided. That is, in the opening 21 c , the third wire 19 c is formed which will be described later. The width of the via shape is not particularly limited. Since it is intended to increase the surface area of the opening, a width smaller than that of the opening 21 g is preferable.
FIG. 4A is a view illustrating the state in which a first barrier layer 16 d composed, for example, of Ta having a thickness of 3 nm to 10 nm is formed, for example, by a PVD method, such as a sputtering method, so as to cover the openings 21 g , 21 b , and 21 c , and the fourth interlayer insulating layer 15 b . Since the Cu wire is formed in the openings 21 g , 21 b , and 21 c , as in the case of the first barrier layer 16 a , a material which reduces Cu diffusion and which has superior adhesion to Cu is used for the first barrier layer 16 d . Incidentally, the first barrier layer 16 d may only be formed when it is necessary.
FIG. 4B is a view illustrating the state in which while the first barrier layer 16 d covers inside walls of the openings 21 g , 21 b , and 21 c , a CuMn alloy layer 17 g composed, for example, of an alloy of Cu and manganese (Mn) having a thickness of 5 nm to 30 nm is formed. Since the CuMn alloy layer 17 g also functions as a seed layer of electrolytic plating which will be described later, the thickness thereof is controlled to an appropriate value to form a buried wire in accordance with the wire dimension. In this embodiment, a CuMn alloy layer having a thickness of 5 nm to 30 nm is formed. The CuMn alloy layer contains 0.2 to 1.0 atomic percent of Mn atoms and preferably contains 0.5 atomic percent or less. In addition, as the CuMn alloy layer 17 g , a layer composed of a mixture including Cu and Mn may also be used as well as the alloy.
In addition, since the surface area of the CuMn alloy layer 17 g is increased by the presence of the openings 21 g , 21 b , and 21 c , the CuMn alloy layer 17 g formed to cover the openings 21 g , 21 b , and 21 c has a small thickness as compared to that of the CuMn alloy layer which is formed to cover the openings 21 a by a sputtering method.
In this operation, the second barrier layer 17 a is formed so as to cover the side walls of the openings 21 g , 21 b , and 21 c . However, in a subsequent operation, since Mn in the second barrier layer 17 a is diffused by a heat treatment and is allowed to react with oxygen in the third interlayer insulating layer 14 b and the fourth interlayer insulating layer 15 b , a CuMn alloy layer including Mn-containing oxides is formed; hence the CuMn alloy layer covering the inside walls of the openings 21 g , 21 b , and 21 c may not have a uniform thickness.
In addition, since the opening 21 c is formed, the CuMn alloy layer 17 g may be formed to have a small thickness as compared to that obtained when the opening 21 c is not formed, that is, when the surface area of the opening is not increased. The total amount of the CuMn alloy layer sputtered on the inside walls of the openings 21 g , 21 b , and 21 c is constant in one sputtering operation. Hence, when the surface area, that is, sputtered area, is large, the thickness of the CuMn alloy layer 17 g formed by sputtering may be decreased.
FIG. 5A is a view illustrating the state in which a conductive layer 18 d composed of Cu having a thickness of 0.5 μm to 2.0 μm is deposited by an electrolytic plating method so as to be buried in the openings 21 g , 21 b , and 21 c . In this embodiment, the conductive layer 18 d composed of Cu is formed; however, the conductive layer 18 d may be an alloy layer including Cu and a metal other than Cu, and as the metal other than Cu, a material is used which does not increase the resistance of a wire even when it is contained in Cu.
Next, a heat treatment is performed at 100 to 250° C. for 1 to 60 minutes. By the heat treatment performed after the conductive layer 18 d is buried in the openings 21 g , 21 b , and 21 c , before Cu is diffused to the second interlayer insulating layer 13 b , the third interlayer insulating layer 14 b , and the fourth interlayer insulating layer 15 b exposed to the side walls of the openings 21 g , 21 b , and 21 c , Mn is diffused to the second interlayer insulating layer 13 b , the third interlayer insulating layer 14 b , and the fourth interlayer insulating layer 15 b . Subsequently, Mn is allowed to react with oxygen in the third interlayer insulating layer 14 b and the fourth interlayer insulating layer 15 b , and a second barrier layer 17 h composed of Mn-containing oxides is formed.
In addition, by this heat treatment, Mn is diffused from the CuMn alloy layer 17 g and is allowed to react with oxygen in the third interlayer insulating layer 14 b and the fourth interlayer insulating layer 15 b exposed to the side walls of the openings 21 g , 21 b , and 21 c . Subsequently, the second barrier layer 17 h composed of Mn-containing oxides is formed on the side walls of the openings 21 g , 21 b , and 21 c each provided with the first barrier layer 16 d to have a thickness of 1 nm to 5 nm. In this embodiment, since the third interlayer insulating layer 14 b is formed of SiOC, the fourth interlayer insulating layer 15 b is formed of SiO 2 , and Mn also reacts with Si, the composition of the Mn-containing oxides forming the second barrier layer 17 h is represented by Mn x Si y O z (x:y:z is 1:1:3 to 1:3:5).
In this case, since the CuMn alloy layer 17 g having a small thickness is formed as described above, the ratio of Mn of the CuMn alloy layer 17 g forming the second barrier layer 17 h on the side walls of the openings 21 g , 21 b , and 21 c is large than that of Mn dissolved in Cu. Hence, an increase in resistance of the Cu wire caused by dissolution of Mn in the conductive layer 18 d may be suppressed.
FIG. 5B is a view illustrating the case in which, for example, by a CMP method, the first barrier layer 16 d , the second barrier layer 17 h , and the conductive layer 18 d are partly removed approximately to the middle of the fourth interlayer insulating layer 15 b by polishing, so that the second wire 19 b composed of Cu is formed in the opening 21 b , and the third wire 19 c composed of Cu is formed in the opening 21 c . The operations described above with reference to FIGS. 2B to 5B are repeatedly performed, so that the semiconductor device 50 a including the multilayer interconnection structure 40 a is formed.
According to the semiconductor device 50 a of the first embodiment, the contact area between the insulating layers containing oxygen and the second barrier layer containing Mn may be increased. Hence, Mn may be sufficiently consumed by the formation of Mn oxides at a portion at which the contact area between the insulating layers and the second barrier layer is increased. As a result, an increase in resistance of the copper wire may be reduced.
In the second embodiment, FIGS. 6A and 6B are views each illustrating the structure of a semiconductor device 50 b having a multilayer interconnection structure 40 b . In the second embodiment, constituents similar to those described in the first embodiment will be designated by the same reference numerals, and a description thereof will be omitted.
FIGS. 6A and 6B each illustrate the structure of the semiconductor device 50 b of the second embodiment. FIG. 6A is a plan view of the semiconductor device 50 b . FIG. 6B is a cross-sectional view taken along the line X-Y illustrated in FIG. 6A .
As illustrated in FIG. 6A , in the semiconductor device 50 b of the second embodiment, reference numeral 15 b indicates a fourth interlayer insulating layer, reference numeral 19 b indicates a second wire (Cu wire), reference numeral 19 c indicates a third wire, and reference numeral 19 e indicates a fourth wire.
The fourth wire 19 e has a concavo-convex portion 22 in a plane direction of a Cu wire. The concavo-convex portion 22 is formed to increase the surface area of the fourth wire 19 e and that of the Cu wire.
As illustrated in FIG. 6B , the semiconductor device 50 b of the second embodiment has a transistor forming layer 60 and the multilayer interconnection structure 40 b . The multilayer interconnection structure 40 b has first wires 19 a , the second wires 19 b , the third wire 19 c , and the fourth wire 19 e . Constituents illustrated in FIG. 6B similar to those described with reference to FIG. 6A are designated by the same reference numerals.
The fourth wire 19 e is formed by burying a conductive layer 18 e in an opening 21 e . The opening 21 e is formed by opening a third interlayer insulating layer 14 b and the fourth interlayer insulating layer 15 b . The opening 21 e is formed so that a conductive material to be filled therein is not electrically connected to the first wire 19 a . The conductive layer 18 e is preferably formed, for example, of copper (Cu).
The concavo-convex portion 22 is formed along the periphery of the opening 21 e . The concavo-convex portion 22 is formed to have an X-Y direction width smaller than the width of the opening 21 e in the X-Y direction. The concavo-convex portion 22 is formed to increase a contact area between insulating layers containing oxygen and a second barrier layer 17 e which will be described below. Hence, as in the first embodiment, Mn may be sufficiently consumed by the formation of Mn oxides at a portion at which the contact area of the second barrier layer 17 e with the third interlayer insulating layer 14 b and the fourth interlayer insulating layer 15 b is increased. Accordingly, the resistance of the Cu wire may be maintained at a low level.
A first barrier layer 16 e and the second barrier layer 17 e are sequentially formed between the opening 21 e and the conductive layer 18 e . The first barrier layer 16 e is formed at the opening 21 e side. The second barrier layer 17 e is formed at the conductive layer 18 e side.
Since the Cu wire is formed in the opening 21 e , a material which reduces Cu diffusion and which has superior adhesion to Cu is used for the first barrier layer 16 e . The first barrier layer 16 e preferably has a thickness of 3 nm to 10 nm. Incidentally, the first barrier layer 16 e may only be formed when it is necessary.
The second barrier layer 17 e is formed between the first barrier layer 16 e and the conductive layer 18 e . Since the third interlayer insulating layer 14 b is formed of SiOC, the fourth interlayer insulating layer 15 b is formed of SiO 2 , and Mn also reacts with Si, the composition of Mn-containing oxides forming the second barrier layer 17 e is represented by Mn x Si y O z (x:y:z is 1:1:3 to 1:3:5). In addition, the second barrier layer 17 e preferably has a thickness of 1 nm to 5 nm.
According to the structure of the semiconductor device 50 b of the second embodiment, besides the structure of the semiconductor device 50 a of the first embodiment, the fourth wire 19 e having a concavo-convex portion in a plane direction of the Cu wire is formed. Hence, even in the case in which a dummy plug may not be formed under the Cu wire, the contact area between the interlayer insulating layers and the second barrier layer containing Mn may be increased. Accordingly, Mn may be sufficiently consumed by the formation of Mn oxides at a portion at which the contact area of the second barrier layer with the insulating layers is increased. As a result, the resistance of the Cu wire may be maintained at a low level.
In the third embodiment, FIGS. 7A and 7B are views each illustrating the structure of a semiconductor device 50 c having a multilayer interconnection structure 40 c . In the third embodiment, constituents similar to those described in the first embodiment will be designated by the same reference numerals, and a description thereof will be omitted.
FIGS. 7A and 7B each illustrate the structure of the semiconductor device 50 c of the third embodiment. FIG. 7A is a plan view of the semiconductor device 50 c . FIG. 7B is a cross-sectional view taken along the line X-Y illustrated in FIG. 7A .
As illustrated in FIG. 7A , in the semiconductor device 50 c of the third embodiment, reference numeral 15 b indicates a fourth interlayer insulating layer, reference numeral 19 b indicates a second wire (Cu wire), reference numeral 19 c indicates a third wire, and reference numeral 19 f indicates a fifth wire.
Slit portions 23 are formed inside the fifth wire 19 f . The slit portions 23 are formed, for example, of an insulating material such as SiO 2 .
However, when the slit portions 23 are formed, since the cross-sectional area of the wire is decreased, an increase in wiring resistance unfavorably occurs. Hence, the rate of decrease in cross-sectional area caused by the formation of the slit portions 23 may be set lower than the rate of increase in resistance caused by Mn intrusion. The slit portions 23 are formed to increase the surface area between the insulating layer containing oxygen and a second barrier layer, which will be described later, in the fifth wire 19 f . For example, the slit portions 23 are preferably formed so as to decrease a 1 μm-wide fifth wire 19 f by approximately 2.5% and so as to decrease a 3 μm-wide fifth wire 19 f by approximately 5%. In addition, the surfaces of the slit portions 23 may be formed inside the fifth wire 19 f . That is, the slit portions 23 may have a grooved shape formed inside the fifth wire 19 f.
As illustrated in FIG. 7B , the semiconductor device 50 c of the third embodiment has a transistor forming layer 60 and the multilayer interconnection structure 40 c . The multilayer interconnection structure 40 c has first wires 19 a , the second wires 19 b , the third wire 19 c , and the fifth wire 19 f . In this embodiment, constituents illustrated in FIG. 7B similar to those described with reference to FIG. 7A are designated by the same reference numerals.
The fifth wire 19 f is formed by burying a conductive layer 18 f in an opening 21 f . The opening 21 f is formed by opening a third interlayer insulating layer 14 b and a fourth interlayer insulating layer 15 b . A conductive material to be filled in the opening 21 f is not electrically connected to the first wire 19 a . The conductive layer 18 f is preferably formed, for example, of copper (Cu).
In the fifth wire 19 f , the slit portions 23 are formed. The slit portions 23 are formed of an insulating material containing oxygen, such as SiO 2 .
However, when the slit portions 23 are formed, since the cross-sectional area of the wire is decreased, an increase in wire resistance unfavorably occurs. Hence, the rate of decrease in cross-sectional area caused by the formation of the slit portions 23 may be set lower than the rate of increase in resistance caused by Mn intrusion. The slit portions 23 are formed to increase the surface area between the insulating material containing oxygen and a second barrier layer 17 f , which will be described below, in the fifth wire 19 f . For example, the slit portions 23 are preferably formed so as to a decrease a 1 μm-wide fifth wire 19 f by approximately 2.5% and so as to decrease a 3 μm-wide fifth wire 19 f by approximately 5%.
A first barrier layer 16 f and the second barrier layer 17 f are sequentially formed between the opening 21 f and the conductive layer 18 f . The first barrier layer 16 f is formed at the opening 21 f side. The second barrier layer 17 f is formed at the conductive layer 18 f side.
Since the Cu wire is formed in the opening 21 f , a material which reduces Cu diffusion and which has superior adhesion to Cu is used for the first barrier layer 16 f . The first barrier layer 16 f preferably has a thickness of 3 nm to 10 nm. Incidentally, the first barrier layer 16 f may only be formed when it is necessary.
The second barrier layer 17 f is formed between the first barrier layer 16 f and the conductive layer 18 f . Since the third interlayer insulating layer 14 b is formed of SiOC, the fourth interlayer insulating layer 15 b is formed of SiO 2 , and Mn also reacts with Si, the composition of Mn-containing oxides forming the second barrier layer 17 f is represented by Mn x Si y O z (x:y:z is in the range of 1:1:3 to 1:3:5). In addition, the second barrier layer 17 f preferably has a thickness of 1 nm to 5 nm.
According to the structure of the semiconductor device 50 c of the third embodiment, besides the structure of the semiconductor device 50 a of the first embodiment, the slit portions 23 are formed. Hence, even when a dummy plug may not be formed under the Cu wire, the contact area between the second barrier layer containing Mn and the insulating material containing oxygen may be increased. Accordingly, Mn may be sufficiently consumed by the formation of Mn oxides at a portion at which the contact area of the second barrier layer with the insulating material is increased. As a result, the resistance of the Cu wire may be maintained at a low level.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the embodiment and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a illustrating of the superiority and inferiority of the embodiment. Although the embodiment(s) of the present invention has (have) been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention. | A semiconductor device includes an insulating layer formed over a semiconductor substrate, the insulating layer including oxygen, a first wire formed in the insulating layer, and a second wire formed in the insulating layer over the first wire and containing manganese, oxygen, and copper, the second wire having a projection portion formed in the insulating layer and extending downwardly but spaced apart from the first wire. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a facsimile apparatus provided with boxes each corresponding to an F-code received through a facsimile transmission procedure, and executing a center-machine application using a corresponding box based on sub-address information and so forth received when image information is received, and a method of controlling such a facsimile apparatus.
2. Description of the Related Art
In the related art, post-office boxes (confidential boxes) for confidential communication are produced using the image storing function of a facsimile apparatus, and, thereby, confidential communication can be performed. An apparatus in which such a function can be achieved is mainly used as a center apparatus for facsimile communication services.
For each confidential box, a box name, a password, and a code number (F-code) for identification are registered. When a transmission side wishes confidential communication, the transmission side transmits a signal SUB for specifying confidential communication, and, also, specifies, in a FIF portion of the signal SUB, the F-code registered for the confidential box which is the destination of the confidential communication, in a pre-transmission procedure. With regard to the format of F-codes, the method of utilizing F-codes and so forth, detailed description will be omitted because that information is prescribed in standards promulgated by the Communications Industry Association of Japan.
Thereby, a center apparatus stores received image information in the confidential box for which the F-code specified by the signal SUB is registered. Then, the user of the destination of the confidential communication makes specification such as to receive a confidential document to the center apparatus, specifies the confidential box from which the confidential document is to be received by inputting an F-code, and inputs a password. Thereby, the confidential document is printed out from the center apparatus.
Further, polling reception by specifying a confidential box can be performed. In this case, a facsimile apparatus which requests polling reception transmits a signal SEP for specifying selective polling reception in a pre-transmission procedure, and, also, sets an F-code to the FIF portion of the signal SEP for specifying a confidential box from which the facsimile apparatus requests the polling reception. Further, the facsimile apparatus transmits a signal PWD to the center apparatus, which signal carries a password for authentication.
(Through the specification and claims of the present application, the term ‘polling’ means the following act:
in a condition in which pieces of information are previously prepared in a server, when a client requests the server to provide one or more of the pieces of information, the server provides the piece(s) of information to the client, for example.)
Thereby, the center apparatus performs authentication using the contents of the received signal PWD for the confidential box for which the specified F-code is registered, and, when the authentication succeeds, transmits the image information stored in the confidential box to the facsimile apparatus which requests the polling reception.
Storage of image information in the confidential box may be performed by using a scanner provided with the center apparatus.
A center apparatus such as that described above has a plurality of types of authentication information and so forth for various management operations such as operation for user restriction and so forth, in addition to a communication application using F-codes. Therefore, an enormous memory resource is required. As a result, the cost of the apparatus is very high.
SUMMARY OF THE INVENTION
The present invention has been devised in consideration of these circumstances, and, an object of the present invention is to provide a facsimile apparatus, the cost of which can be reduced, and a method of controlling such a facsimile apparatus.
A facsimile apparatus according to the present invention, provided with boxes each corresponding to an F-code which is received through a facsimile transmission procedure, executing a center-machine application using the corresponding box based on sub-address information when receiving image information, the apparatus comprising:
an F-code input requesting portion which requests a user to input an F-code when the user operates the apparatus for performing transmission; and a control portion which searches for the box for which the F-code is registered, the value of which F-code agrees with the value of the F-code input by the user, and, only when finding the box, agrees to accept the transmission operation performed by the user, and registers, in document managing information for managing a transmission job relating to the transmission operation, identification information for the box as authentication information.
The facsimile apparatus may further comprise a transmission control portion which, when image information is transmitted, reads an F-code or a box name registered for the box corresponding to the authentication information registered in the document managing information, and inserts information indicating the F-code in at least any one page of the image information.
A facsimile apparatus according to another aspect of the present invention, provided with boxes each corresponding to an F-code which is received through a facsimile transmission procedure, executing a center-machine application using the corresponding box based on sub-address information when receiving image information, the apparatus comprising:
an F-code input requesting portion which requests a user to input an F-code when the user operates the apparatus for producing a polling document; and a control portion which searches for the box for which the F-code is registered, the value of which F-code agrees with the value of the F-code input by the user, and, only when finding the box, agrees to accept the polling document producing operation performed by the user, and registers, in document managing information for managing a job relating to the polling document producing operation, identification information for the box as authentication information.
The facsimile apparatus may further comprise a transmission control portion which, when a call is coming and polling reception is requested by the call originating terminal, reads the F-code or box name registered for the box corresponding to the authentication information registered in the document managing information corresponding to the specified document to be transmitted, and inserts information indicating the F-code or box name in at least any one page of the image information to be transmitted.
A facsimile apparatus according to another aspect of the present invention, provided with boxes each corresponding to an F-code which is received through a facsimile transmission procedure, executing a center-machine application using the corresponding box based on sub-address information when receiving image information, the apparatus comprising:
an F-code input requesting portion which requests a user to input an F-code either when the user operates the apparatus for performing transmission or when the user operates the apparatus for producing a polling document; a control portion which searches for the box for which the F-code is registered, the value of which F-code agrees with the value of the F-code input by the user, and, only when finding the box, either agrees to accept the transmission operation performed by the user, and registers, in document managing information for managing a transmission job relating to the transmission operation, identification information for the box as authentication information, or agrees to accept the polling document producing operation performed by the user, and registers, in document managing information for managing a job relating to the polling document producing operation, identification information for the box as authentication information.
The facsimile apparatus may further comprise a transmission control portion which, when image information is transmitted, reads the F-code or box name registered for the box corresponding to the authentication information registered in the document managing information, and inserts information indicating the F-code or box name in at least any one page of the image information, but, when a call is coming and polling reception is requested by the call originating terminal, reads the F-code registered for the box corresponding to the authentication information registered in the document managing information corresponding to the specified document to be transmitted, and inserts information indicating the F-code or box name in at least any one page of the image information to be transmitted.
Thereby, the box information mainly relating to reception operation is used for user authentication performed when user restriction or the like in transmission operation is performed. Accordingly, it is not necessary to further provide information for the user authentication. As a result, it is possible to reduce the necessary memory capacity of a system memory or the like, and to reduce the cost of the apparatus.
Further, information (F-code or box name) which is obtained by referring to the box number is used as transmission side information to be inserted in to an image when the image information is transmitted. As a result, it is not necessary to use special information as information to specify the transmission side information, and it is possible to limit the size of the document managing information to a small one. Thereby, it is possible to reduce the necessary memory capacity of the system memory or the like, and to reduce the cost of the apparatus.
Further, information (F-code or box name) which is obtained by referring to the box number is used as transmission side information to be inserted into an image when polling transmission is performed. As a result, it is not necessary to use special information as information to specify the transmission side information, and it is possible to limit the size of the document managing information to a small one. Thereby, it is possible to reduce the necessary memory capacity of the system memory or the like, and to reduce the cost of the apparatus.
Further, because user authentication and specification of the box can be performed by using a single F-code in common, it is very easy for the user to use the apparatus and the apparatus is very convenient for the user in comparison to a case where a plurality of pieces of information for authentication are used.
Other objects and further features of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an example of an arrangement of a Group 3 facsimile apparatus in one embodiment of the present invention;
FIG. 2 illustrates one example of a set of box information;
FIG. 3 illustrates one example of a set of document managing information;
FIGS. 4 through 11 illustrate examples of displayed pictures;
FIGS. 12 and 13 illustrate examples of images to be transmitted;
FIGS. 14 through 17 are flow charts showing one example of processing performed by the Group 3 facsimile apparatus in the embodiment of the present invention when a user performs transmission operation or polling document producing operation;
FIG. 18 is a flow chart showing one example of confidential box searching processing;
FIG. 19 is a flow chart showing one example of box with password searching processing;
FIG. 20 is a flow chart showing one example of all box searching processing;
FIGS. 21 through 23 are a flow chart showing one example of processing performed by the Group 3 facsimile apparatus in the embodiment of the present invention when a call is coming;
FIG. 24 illustrates another example of a set of box information;
FIG. 25 illustrates another example of a set of box information;
FIG. 26 is a flow chart showing another example of the confidential box searching processing
FIG. 27 is a flow chart showing another example of the box with password searching processing; and
FIG. 28 is a flow chart showing another example of the all box searching processing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an example of an arrangement of a Group 3 facsimile apparatus in one embodiment of the present invention.
In the figure, a system control portion 1 performs control processing for each portion of the Group 3 facsimile apparatus, and various control processing such as processing for a facsimile transmission control procedure, and so forth. A system memory 2 stores therein control processing programs executed by the system control portion 1 , various data needed for executing the processing programs, and so forth, and, also, acts as a work area for the system control portion 1 . A parameter memory 3 stores therein various information particular to this Group 3 facsimile apparatus (for example, registered information for a one-touch dialing function and so forth). A clock circuit 4 outputs information of the current time.
A scanner 5 reads an original image in a predetermined resolution. A plotter 6 prints out an image in a predetermined resolution. An operation/indication portion 7 is used for a user to operate this Group 3 facsimile apparatus, and includes various keys, and various indicators.
A coding/decoding portion 8 codes and compresses an image signal, and decodes coded and compressed image information into an original image signal. An image storing device 9 stores therein many pages of coded and compressed image information, and achieves the above-described confidential-box functions.
A Group 3 facsimile modem 10 achieves Group 3 facsimile modem functions, and, has low-rate modem functions (V. 21 modem) for transmitting/receiving transmission procedure signals, and high-rate modem functions (V. 17 modem, V. 34 modem, V. 29 modem, V. 27ter modem and so forth) for mainly transmitting/receiving image information.
A network control device 11 is used for connecting this Group 3 facsimile apparatus to a public network (PSTN) and has automatic calling/call receiving functions.
These system control portion 1 , system memory 2 , parameter memory 3 , clock circuit 4 , scanner 5 , plotter 6 , operation/indication portion 7 , coding/decoding portion 8 , image storing device 9 , Group 3 facsimile modem 10 and network control device 11 are connected to an internal bus 12 , and the internal bus 12 is mainly used for transmitting/receiving data between the respective portions.
However, data transmission is performed directly between the network control device 11 and Group 3 facsimile modem 10 .
This Group 3 facsimile apparatus is provided with a plurality of boxes using the image storing device 9 . For each box, box information such as that shown in FIG. 2 is produced for managing the respective boxes, and is stored in the system memory 2 . Actual image information is stored in the image storing device 9 , and, information specifying which box the image information belongs to is added to storage managing information (not shown in the figures) which is provided for managing thus stored image information. Thereby, storage of the image information in the respective boxes, and so forth are managed.
One set of box information consists of registered F-code entry, password entry, box name entry, box-type information entry expressing a type of a box (‘confidential box’, ‘bulletin board’, ‘relay box’ or the like), and one or more distribution-destination information entries.
A predetermined number of boxes are previously prepared, and, by user's operation, whether or not the box is used is registered. Such a user's operation for using a box is referred to as a ‘box opening operation’, hereinafter. (To perform such an operation for using a box is referred to as ‘to open the box’, hereinafter.)
The contents of the respective entries of one set of the box information are registered when it is needed. Accordingly, there may be a confidential box for which no password is registered, for example.
In this Group 3 facsimile apparatus, document managing information for managing transmission/reception jobs is produced, and is stored in the system memory 2 . FIG. 3 shows an example of this document managing information.
One set of document managing information consists of a document number entry for identifying each document, a production date/time entry indicating the date/time at which the document was produced, a performance date/time entry indicating the date/time at which communication was performed, a document type entry indicating the type of the document (‘to-be-transmitted document’, ‘received document’, ‘polling document’ or the like), an identification information entry indicating information for identifying a box (for example, a box number) which was used for authentication of the user who produced the document, or the like, an image information entry indicating reference information for the image information (document information) in the image storing device 9 corresponding to this set of document managing information, a box number entry indicating a box in which the document information corresponding to this set of document managing information is stored, and a performance result entry indicating the result of performance of communication.
Depending on the attribute of the document corresponding to a set of document managing information, effective information may not be registered as each entry of the set of document managing information. For example, the box number entry is not used for a to-be-transmitted document.
When facsimile transmission is performed using this Group 3 facsimile apparatus, a picture such as that shown in FIG. 4 is displayed, as an initial picture, on a display screen of the operation/indication portion 7 .
When a to-be-transmitted original is set in this state, the contents of the displayed picture changes into that shown in FIG. 5 , and, when a destination is input in accordance with the displayed guidance, the contents of the input destination is displayed, and, also, the guidance for subsequent operation is displayed, as shown in FIG. 6 .
Then, because it is necessary to input sender's information for user authentication, ‘extension transmission’ displayed as shown in FIG. 6 is selected. Thereby, the displayed picture changes into that shown in FIG. 7 . From this picture, ‘04 sender's information’ is selected. Thereby, the displayed picture changes into that shown in FIG. 8 , and a code number is requested to be input.
Then, a user inputs an F-code as the code number. In response to this inputting operation by the user, the thus-input contents are displayed as shown in FIG. 9 . For example, the F-code is the F-code which was registered for a box which the user opened for himself/herself.
When an F-code is input as mentioned above, the Group 3 facsimile apparatus searches for the set of box information in which the same value as the thus-input F-code is registered as the F-code entry thereof. Then, when the thus-searched-for set of box information is found and the search is succeeded, the box name is read from the thus-obtained set of box information, the guidance shown in FIG. 10 is displayed, and the user is requested to confirm it.
Then, when the user selects ‘YES’, the box number of this box is used as the identification information for the transmission operation, and, also, the user authentication is succeeded, and the subsequent transmission operation can be performed.
When a code number is input, another person may stole a glance at and abuse the code number when the input contents are displayed as shown in FIG. 9 . In order to prevent such a situation, it is preferable that the input contents are concealed as a result of a string having the number of characters (in this case, a string of ‘*’), which number is the same as that of the input code number, being instead displayed as shown in FIG. 11 .
Further, when image information is transmitted as a result of the above-mentioned transmission operation being performed, the contents of an F-code set by the user at this time is displayed in the ‘sending code’ section as shown in FIG. 12 (as a display image of the F-code) or the box number of the box set by the user at this time is displayed in the ‘sender section’ as shown in FIG. 13 (as a display image of the box number). The type of this displayed information depends on the set contents of the Group 3 facsimile apparatus.
This method of performing authentication of a user using the box information can also be used not only when transmission operation is performed but also when a document for polling transmission is produced.
Thus, in this embodiment, the box information mainly relating to reception operation is used and user authentication is performed for user restriction or the like in transmission operation. Accordingly, it is not necessary to further provide information for the user authentication. As a result, it is possible to reduce the necessary memory capacity of the system memory 2 , and to reduce the cost of the apparatus.
FIGS. 14 , 15 and 16 show an example of processing performed by this Group 3 facsimile apparatus when a user performs transmission operation or polling document producing operation.
In this processing, the Group 3 facsimile apparatus monitors whether or not transmission operation or polling document producing operation is instructed to perform, in the loop of determinations of the steps 101 and 102 shown in FIG. 14 . Then, when transmission operation is performed and the result of the determination of the step 101 becomes YES, the Group 3 facsimile apparatus requests the user to input a transmission destination and the user inputs the transmission destination (in a step 103 ).
Then, the Group 3 facsimile apparatus requests the user to input a transmission side information (sender's information) and the user inputs the transmission side information (in a step S 104 ). When this step 104 is not interrupted (NO of a determination of a step 105 ), the contents of the thus-input transmission side information are verified.
Specifically, first, it is examined whether or not ‘only confidential boxes’ are specified as targets of search (in a determination of a step 106 ). Then, when the result of the determination of the step 106 is YES, predetermined confidential box searching processing (in a step 107 , described later) is performed, and, it is examined whether or not the input transmission side information is registered as the F-code for any confidential box.
Further, when ‘only confidential boxes’ are not specified as targets of search and the result of the determination of the step 106 is NO, it is examined whether or not ‘only boxes with passwords’ are specified as targets of search (in a determination of a step 108 ).
When the result of the determination of the step 108 is YES, predetermined box with password searching processing (in a step 109 , described later) is performed, and, it is examined whether or not the input transmission side information is registered as the F-code for any box with password.
Further, when neither ‘only confidential boxes’ nor ‘only boxes with passwords’ are specified targets of search and the result of the determination of the step 108 is NO, it is determined that ‘all the boxes’ are specified as targets of search.
Accordingly, in this case, predetermined all box searching processing (in a step 110 , described later) is performed, and it is examined whether or not the input transmission side information is registered as the F-code for any box.
When the searching processing in the step 107 , 109 or 110 is completed, it is determined whether the result of the search is ‘success’ (in a determination of a step 111 ). When the result of the search is ‘failure’, and the result of the determination of the step 111 is NO, the processing returns to the step 104 , and the user is requested again to input transmission side information.
When the result of the search is ‘success’, and the result of the determination of the step 111 is YES, the Group 3 facsimile apparatus performs transmission operation which is requested at this time.
First, the Group 3 facsimile apparatus produces a set of document managing information such as that described above for a transmission job to be performed at this time (in a step 112 ).
Then, the Group 3 facsimile apparatus originates a call to the specified destination (in a step 115 ), performs a predetermined pre-transmission procedure and sets transmission functions to be used in the transmission together with the destination terminal (in a step 116 ), performs a predetermined modem training procedure, and determines the modem rate to be used in the transmission.
In the Group 3 facsimile apparatus, it is previously set whether an F-code is to be added or a box name is to be added, as identification information of a sender, to image information to be transmitted.
Then, it is examined that whether or not it is set that an F-code is to be added (in a determination of a step 118 ). When, the result of the determination of the step 118 is YES, the F-code is read from the set of box information identified using the box number registered as the identification information entry of the set of document managing information of this time (in a step S 119 ).
Then, the Group 3 facsimile apparatus reads an original to be transmitted set in the scanner 5 (in a step 120 ), produces a display image of the F-code and inserts the display image in a predetermined area of the original image read in the step 120 (in a step 121 ), codes and compresses the thus-obtained image information through the coding/decoding portion 8 and transmits the thus-obtained image information to the destination terminal (in a step S 122 ).
When completing transmission of one page of the image information, the Group 3 facsimile apparatus examines whether or not there is another page to be subsequently transmitted (in a determination of a step 123 ), and, when another original is set in the scanner 5 and the result of the determination of the step 123 is YES, transmits a signal MPS as a post-message signal to the destination terminal (in a step 124 ), and, when receiving a response signal from the destination terminal (in a step 125 ), the processing returns to the step 120 , and the Group 3 facsimile apparatus transmits the page of image information to the destination terminal.
When transmission of all the pages of image information is completed and the result of the determination of the step 123 is NO, the Group 3 facsimile apparatus transmits a signal EOP as a post-message signal to the destination terminal (in a step 126 ), and, when receiving a response signal from the destination terminal (in a step 127 ), transmits a signal DCN to the destination terminal (in a step 128 ) and releases the line (in a step S 129 ).
Then, based on the result of the transmission at this time, the Group 3 facsimile apparatus updates the set of document managing information (in a step 130 ), and completes the transmission operation.
When it is set that the box name is to be added and the result of the determination of the step 118 is NO, the Group 3 facsimile apparatus reads the box name from the set of box information identified using the box number registered as the identification information entry of the set of document managing information of this time (in a step 131 ).
Then, the Group 3 facsimile apparatus reads an original to be transmitted set in the scanner 5 (in a step 132 ), produces a display image of the box name and inserts the display image in a predetermined area of the original image read in the step 132 (in a step 133 ), codes and compresses the thus-obtained image information through the coding/decoding portion 8 and transmits the thus-obtained image information to the destination terminal (in a step S 134 ).
When completing transmission of one page of the image information, the Group 3 facsimile apparatus examines whether or not there is another page to be subsequently transmitted (in a determination of a step 135 ), and, when another original is set in the scanner 5 and the result of the determination of the step 135 is YES, transmits a signal MPS as a post-message signal to the destination terminal (in a step 136 ), and, when receiving a response signal from the destination terminal (in a step 137 ), the processing returns to the step 132 , and the Group 3 facsimile apparatus transmits the page of image information to the destination terminal.
When transmission of all the pages of image information is completed and the result of the determination of the step 135 is NO, the Group 3 facsimile apparatus transmits a signal EOP as a post-message signal to the destination terminal (in a step 138 ), and, when receiving a response signal from the destination terminal (in a step 139 ), transmits a signal DCN to the destination terminal (in a step 140 ), the processing shifts to the step 129 , and the Group 3 facsimile apparatus performs the subsequent steps.
When the user cancels the operation of inputting the transmission side information halfway and the result of the determination of the step 105 is YES, the Group 3 facsimile apparatus discontinues the transmission operation at the time.
When a user operates the Group 3 facsimile apparatus for producing a polling transmission document and the result of the determination of the step 102 is YES, the Group 3 facsimile apparatus requests the user to input transmission side information (sender's information) and the user inputs the transmission side information (in a step S 141 ). When this step 141 is not interrupted (NO of a determination of a step 142 ), the contents of the thus-input transmission side information are verified.
Specifically, first, it is examined whether or not ‘only confidential boxes’ are specified as targets of search (in a determination of a step 143 ). Then, when the result of the determination of the step 143 is YES, the predetermined confidential box searching processing (in a step 144 , described later) is performed, and, it is examined whether or not the input transmission side information is registered as the F-code for any confidential box.
Further, when ‘only confidential boxes’ are not specified as targets of search and the result of the determination of the step 143 is NO, it is examined whether or not ‘only boxes with passwords’ are specified as targets of search (in a determination of a step 145 ).
When the result of the determination of the step 145 is YES, the predetermined box with password searching processing (in a step 146 , described later) is performed, and, it is examined whether or not the input transmission side information is registered as the F-code for any box with password.
Further, when neither ‘only confidential boxes’ nor ‘only boxes with passwords’ are specified as targets of search and the result of the determination of the step 145 is NO, it is determined that all the boxes are specified as targets of search.
Accordingly, in this case, the predetermined all box searching processing (in a step 147 , described later) is performed, and it is examined whether or not the input transmission side information is registered as the F-code for any box.
When the searching processing in the step 144 , 146 or 147 is completed, it is determined whether or not the result of the search is ‘success’ (in a determination of a step 148 ). When the result of the search is ‘failure’, and the result of the determination of the step 148 is NO, the processing returns to the step 141 , and the Group 3 facsimile apparatus requests the user to again input transmission side-information.
When the result of the search is ‘success’, and the result of the determination of the step 148 is YES, the Group 3 facsimile apparatus performs polling document producing operation which is requested at the time.
First, the Group 3 facsimile apparatus reads each original set in the scanner 5 , codes and compresses the thus-obtained image information through the coding/decoding portion 8 , and stores the thus-obtained image information in the image storing device 9 (in a step 149 ).
Then, the Group 3 facsimile apparatus produces and stores a set of document managing information such as that described above for a job of transmitting the document information stored in the step 149 (in a step 150 ), and completes the polling document producing operation. The box number obtained as a result of the searching processing in the step 144 , 146 or 147 can be used as the box number of the set of document managing information produced in the step 150 .
When the user cancels the operation of inputting the transmission side information halfway and the result of the determination of the step 142 is YES, the Group 3 facsimile apparatus discontinues the polling document producing operation at the time.
Thus, in this embodiment of the present invention, information (F-code or box name) which is obtained by referring to the box number is used as transmission side information to be inserted into an image when the image information is transmitted. As a result, it is not necessary to use special information as information to specify transmission side information, and it is possible to limit the size of the set of document managing information to a small one. Thereby, it is possible to reduce the necessary memory capacity of the system memory 2 , and to reduce the cost of the apparatus.
In the above-described processing, the display image of the F-code or the display image of the box name is inserted in each page of the image information to be transmitted. However, the method of inserting the display image of the F-code or the display image of the box name into the image information to be transmitted is not limited to this. Instead, it is also possible that the display image of the F-code or the display image of the box name is inserted in at least any one page of the image information to be transmitted.
FIG. 18 shows one example of the confidential box searching processing (each of the steps 107 and 144 ).
First, each parameter of the searching processing is initialized (in a step 201 ).
Then, one box (set of box information) is selected (in a step 202 ), it is examined whether or not the box type entry of the thus-selected set of box information is ‘confidential box’ (in a determination of a step 203 ), then, when the result of the determination of the step 203 is YES, it is examined whether or not the box has been already opened (in a determination of a step 204 ), and, then, when the result of the determination of the step 204 is YES, it is examined whether or not the value registered as the F-code entry of the set of box information agrees with the value of the F-code which is the target of the search (in a determination of a step 205 ).
When the result of the determination of the step 205 is YES, the confidential box searching processing at this time is finished in normality. That is, in this case, as the result of the searching processing, ‘success’ is returned.
When the result of the determination of the step 203 is NO, the result of the determination of the step 204 is NO or the result of the determination of the step 205 is NO, it is determined whether or not another set of box information is left unexamined (in a determination of a step 206 ). When the result of the determination of the step 206 is YES, the processing returns to the step 202 , and the same examination is performed on the another set of box information.
When it is determined that there is not any set of box information, the F-code entry of which agrees with the F-code which is the target of the search, after the contents of the sets of box information of all the already-opened confidential boxes are examined, and the result of the determination of the step 206 is NO, the confidential box searching processing is finished in error. That is, in this case, ‘failure’ is returned as the result of the search.
Thus, in the confidential box searching processing, because the targets to be searched are limited to the already-opened confidential boxes, the processing speed is high in comparison to the case where all the boxes are the targets to be searched.
FIG. 19 shows one example of the box with password searching processing (each of the steps 109 and 146 ).
First, each parameter of the searching processing is initialized (in a step 301 ).
Then, one box (set of box information) is selected (in a step 302 ), it is examined whether or not the box type entry of the thus-selected set of box information is ‘box with password’ (in a determination of a step 303 ), then, when the result of the determination of the step 303 is YES, it is examined whether or not the box has been already opened (in a determination of a step 304 ), and, then, when the result of the determination of the step 304 is YES, it is examined whether or not the value registered as the F-code entry of the set of box information agrees with the value of the F-code which is the target of the search (in a determination of a step 305 ).
When the result of the determination of the step 305 is YES, the box with password searching processing at this time is finished in normality. That is, in this case, as the result of the searching processing, ‘success’ is returned.
When the result of the determination of the step 303 is NO the result of the determination of the step 304 is NO or the result of the determination of the step 305 is NO, it is examined whether or not another set of box information is left unexamined (in a determination of a step 306 ). When the result of the determination of the step 306 is YES, the processing returns to the step 302 , and the same examination is performed on the another set of box information.
When it is determined that there is not any set of box information, the F-code entry of which agrees with the F-code which is the target of the search, after the contents of the sets of box information of all the already-opened boxes with passwords are examined, and the result of the determination of the step 306 is NO, the box with password searching processing is finished in error. That is, in this case, ‘failure’ is returned as the result of the search.
Thus, in the box with password searching processing, because the targets to be searched are limited to the already-opened boxes with passwords, the processing speed is high in comparison to the case where all the boxes are the targets to be searched.
Further, in the box with password searching processing, when the result of the determination of the step 305 becomes YES, the Group 3 facsimile apparatus requests the user to input password, and performs authentication processing in which the input password is compared with the password registered in the set of box information. Thereby, it is possible to perform more positive user authentication.
FIG. 20 shows one example of the all box searching processing (each of the steps 110 and 147 ).
First, each parameter of the searching processing is initialized (in a step 401 ).
Then, one box (set of box information) is selected (in a step 402 ), it is examined whether or not the box has been already opened (in a determination of a step 403 ), and, then, when the result of the determination of the step 403 is YES, it is examined whether or not the value registered as the F-code entry of the set of box information agrees with the value of the F-code which is the target of the search (in a determination of a step 404 ).
When the result of the determination of the step 404 is YES, the all box searching processing at this time is finished in normality. That is, in this case, as the result of the searching processing, ‘success’ is returned.
When the result of the determination of the step 403 is NO or the result of the determination of the step 404 is NO, it is determined whether or not another set of box information is left unexamined (in a determination of a step 405 ). When the result of the determination of the step 405 is YES, the processing returns to the step 402 , and the same examination is performed on the another set of box information.
When it is determined that there is not any set of box information, the F-code entry of which agrees with the F-code which is the target of the search; after the contents of the sets of box information of all the already-opened boxes are examined, and the result of the determination of the step 405 is NO, the all box searching processing is finished in error. That is, in this case, ‘failure’ is returned as the result of the search.
FIGS. 21 , 22 and 23 show one example of processing performed by this Group 3 facsimile apparatus when a call is coming to the Group 3 facsimile apparatus.
When detecting a call incoming, the Group 3 facsimile apparatus responds to the call, performs a predetermined pre-transmission procedure with the calling terminal, and performs confirming and setting of transmission functions and so forth (in a step 502 ).
Then, the Group 3 facsimile apparatus examines whether or not a polling request is made by the call originating terminal (in a determination of a step 503 ), and, when the result of the determination of the step 503 is NO, performs ordinary processing (in a step 504 ) which is to be performed when a call is coming, and finishes the operation which is to be performed when a call is coming.
When a polling request is made by the call originating terminal and the result of the determination of the step 503 is YES, the Group 3 facsimile apparatus performs the modem training procedure, determines the modem rate to be used (in a step 505 ), and selects a file to be transmitted at this time (in a step 506 ). For example, when an F-code is specified by the call originating terminal through a signal SEP, the Group 3 facsimile apparatus selects image information in the box corresponding to that F-code as the file to be transmitted. On the other cases, the Group 3 facsimile apparatus selects image information which is prepared for free polling as the file to be transmitted.
Then, the Group 3 facsimile apparatus examines whether or not it is set in itself that an F-code is to be added as the transmission side information (in a determination of a step 507 ), and, when the result of the determination of the step 507 is YES, the Group 3 facsimile apparatus reads the F-code from the set of box information having the box number registered as the identification information entry of the set of document managing information corresponding to the file selected in the step 506 (in a step 508 ).
Then, the Group 3 facsimile apparatus reads one page of image information of the file selected in the step 506 from the image storing device 9 , decodes the thus-read image information into the original image information through the coding/decoding portion 8 (in a step 509 ), and, inserts a display image of the F-code produced based on the F-code read in the step 508 into a predetermined display area of the page of the image obtained in the step 509 (in a step 510 ), and, codes and compresses the thus-obtained image information, and transmits the thus-obtained image information to the call originating terminal (in a step 511 ).
When finishing transmission of the page of image information, the Group 3 facsimile apparatus examines whether or not there is any other page to be transmitted (in a determination of a step 512 ). When there is a page to be transmitted subsequently and the result of the determination of the step 512 is YES, the Group 3 facsimile apparatus transmits a signal MPS as a post-message signal to the call originating terminal (in a step 513 ), and, when receiving a response signal from the call originating terminal (in a step S 514 ), the processing returns to the step 509 , and the Group 3 facsimile apparatus transmits the page of image information to the call originating terminal.
When finishing transmission of all the pages of image information and the result of the determination of the step 512 is NO, the Group 3 facsimile apparatus transmits a signal EOP as a post-message signal to the call originating terminal (in a step 515 ), and, when receiving a response signal from the call originating terminal in a step 516 , transmits a signal DCN to the call originating terminal (in a step 517 ), and releases the line (in a step 518 ).
Then, the Group 3 facsimile apparatus updates the contents of the set of document managing information based on the result of the polling transmission at this time (in a step 519 ), and finishes the polling transmission operation.
When it is set in the Group 3 facsimile apparatus itself that the box name is to be added as the transmission side information and the result of the determination of the step 507 is NO, reads the box name from the set of box information having the box number registered as the identification information entry of the set of document managing information corresponding to the file selected in the step 506 (in a step 520 ).
Then, the Group 3 facsimile apparatus reads one page of image information of the file selected in the step 506 from the image storing device 9 , decodes the thus-read image information into the original image information through the coding/decoding portion 8 (in a step 521 ), and, inserts a display image of the box name produced based on the box name read in the step 520 into a predetermined display area of one page of image obtained in the step 521 (in a step 522 ), and, codes and compresses the thus-obtained image information, and transmits the thus-obtained image information to the call originating terminal (in a step 523 ).
When finishing transmission of the page of image information, the Group 3 facsimile apparatus examines whether or not there is any other page to be transmitted (in a determination of a step 524 ). When there is a page to be transmitted subsequently and the result of the determination of the step 524 is YES, the Group 3 facsimile apparatus transmits a signal MPS as a post-message signal to the call originating terminal (in a step 525 ), and, when receiving a response signal from the call originating terminal (in a step 526 ), the processing returns to the step 521 , and the Group 3 facsimile apparatus transmits the page of image information.
When finishing transmission of all the pages of image information and the result of the determination of the step 524 is NO, the Group 3 facsimile apparatus transmits a signal EOP as a post-message signal to the call originating terminal (in a step 527 ), and, when receiving a response signal from the call originating terminal (in a step 528 ), transmits a signal DCN to the call originating terminal (in a step 529 ), the processing returns to the step 518 , and the Group 3 facsimile apparatus performs the subsequent steps.
Thus, in this embodiment of the present invention, information (F-code or box name) which is obtained by referring to the box number is used as the transmission side information to be inserted in to the image when polling transmission is performed. As a result, it is not necessary to use special information as information to specify the transmission side information, and it is possible to limit the size of the set of document managing information to a small one. Thereby, it is possible to reduce the necessary memory capacity of the system memory 2 , and to reduce the cost of the apparatus.
Further, because user authentication and specification of the box can be performed by using a single F-code in common, it is very easy for a user to use the apparatus and the apparatus is very convenient for the user in comparison to a case where a plurality of pieces of information for authentication are used.
In the above-described processing, the display image of the F-code or the display image of the box name is inserted in each page of the image information to be transmitted. However, the method of inserting the display image of the F-code or the display image of the box name into the image information to be transmitted is not limited to this. Instead, it is also possible that the display image of the F-code or the display image of the box name is inserted in at least any one page of the image information to be transmitted.
In the above-described embodiment, sets of box information each such as that shown in FIG. 2 are used. However, instead, sets of box information each such as that shown in FIG. 24 may be used. In the set of box information shown in FIG. 24 , the box type entry is deleted in comparison to that shown in FIG. 2 . Accordingly, the searching processing using the F-code input by a user is either one of the box with password searching processing and the all box searching processing.
In this case, in the box with password searching processing, only the boxes for which a previously specified effective password or previously specified respective effective passwords are registered are treated as targets of the search. Further, when the box for which the F-code having the value same as that of the F-code input by the user is found through the search, authentication operation using the password registered for the thus-found box is performed as mentioned above. For example, the Group 3 facsimile apparatus requests the user to input a password, and compares the thus-input password with the passwords registered for the found box. Then, only when the authentication operation succeeds, that is, in the above-mentioned example, only when the passwords input by the user agrees with the password registered for the found box, the box with password searching processing completes in normality, and, the Group 3 facsimile apparatus performs the job (transmission of image information or production of polling document) requested by the user through the operation performed by the user on the Group 3 facsimile apparatus.
Contrary thereto, sets of box information each such as that shown in FIG. 25 may be used, instead. In the set of box information shown in FIG. 25 , a code number allowance/rejection entry for specifying whether or not this set of box information can be used for user authentication is added in comparison to that shown in FIG. 2 .
FIG. 26 shows one example of the confidential box searching processing (each of the steps 107 and 144 ) performed in this case.
First, each parameter of the searching processing is initialized (in a step 601 ).
Then, one box (set of box information) is selected (in a step 602 ), it is examined whether or not the box type entry of the thus-selected set of box information is ‘confidential box’ (in a determination of a step 603 ), then, when the result of the determination of the step 603 is YES, it is examined whether or not the box has been already opened (in a determination of a step 604 ), and, then, when the result of the determination of the step 604 is YES, it is examined whether or not the value registered as the F-code entry of the set of box information agrees with the value of the F-code which is the target of the search (in a determination of a step 605 ).
When the result of the determination of the step 605 is YES, it is examined whether or not the contents of the code number allowance/rejection entry of the set of box information is ‘allowance’ (in a determination of a step 606 ), and, when the result of the determination of the step 606 is YES, the confidential box searching processing at this time is finished in normality. That is, in this case, as the result of the searching processing, ‘success’ is returned.
When the result of the determination of the step 603 is NO, the result of the determination of the step 604 is NO or the result of the determination of the step 605 is NO, it is determined whether or not another set of box information is left unexamined (in a determination of a step 607 ). When the result of the determination of the step 607 is YES, the processing returns to the step 602 , and the same examination is performed on the another set of box information.
When it is determined that there is not any set of box information, the F-code entry of which agrees with the F-code which is the target of the search, after the contents of the sets of box information of all the already-opened confidential boxes are examined, and the result of the determination of the step 607 is NO, or the result of the determination of the step 606 is NO, the confidential box searching processing is finished in error. That is, in this case, ‘failure’ is returned as the result of the search.
FIG. 27 shows one example of the box with password searching processing (each of the steps 109 and 146 ) performed in the case where sets of box information each such as that shown in FIG. 25 are used.
First, each parameter of the searching processing is initialized (in a step 701 ).
Then, one box (set of box information) is selected (in a step 702 ), it is examined whether or not the box type entry of the thus-selected set of box information is ‘box with password’ (in a determination of a step 703 ), then, when the result of the determination of the step 703 is YES, it is examined whether or not the box has been already opened (in a determination of a step 704 ), and, then, when the result of the determination of the step 704 is YES, it is examined whether or not the value registered as the F-code entry of the set of box information agrees with the value of the F-code which is the target of the search (in a determination of a step 705 ).
When the result of the determination of the step 705 is YES, it is examined whether or not the code number allowance/rejection entry of the set of box information is ‘allowance’ (in a determination of a step 706 ), and, when the result of the determination of the step 706 is YES, the box with password searching processing at this time is finished in normality. That is, in this case, as the result of the searching processing, ‘success’ is returned.
When the result of the determination of the step 703 is NO, the result of the determination of the step 704 is NO or the result of the determination of the step 705 is NO, it is examined whether or not another set of box information is left unexamined (in a determination of a step 707 ). When the result of the determination of the step 707 is YES, the processing returns to the step 702 , and the same examination is performed on the another set of box information.
When it is determined that there is not any set of box information, the F-code entry of which agrees with the F-code which is the target of the search, after the contents of the sets of box information of all the already-opened boxes with passwords are examined, and the result of the determination of the step 707 is NO, or the result of the determination of the step 706 is NO, the box with password searching processing is finished in error. That is, in this case, ‘failure’ is returned as the result of the search.
FIG. 28 shows one example of the all box searching processing (each of the steps of 110 and 147 ) performed in the case where sets of box information each such as that shown in FIG. 25 are used.
First, each parameter of the searching processing is initialized (in a step 801 ).
Then, one box (set of box information) is selected (in a step 802 ), it is examined whether or not the box has been already opened (in a determination of a step 803 ), then, when the result of the determination of the step 803 is YES, it is examined whether or not the value registered as the F-code entry of the thus-selected set of box information agrees with the value of the F-code which is the target of the search (in a determination of a step of a step 804 ).
When the result of the determination of the step 804 is YES, it is determined whether the contents of the code number allowance/rejection entry of the set of box information is ‘allowance’ (in a determination of a step of a step 805 ), and, when the result of the determination of the step 805 is YES, the all box searching processing at this time is finished in normality. That is, in this case, as the result of the searching processing, ‘success’ is returned.
When the result of the determination of the step 803 is NO or the result of the determination of the step 804 is NO, it is determined whether or not another set of box information is left unexamined (in a determination of a step of a step 806 ). When the result of the determination of the step 806 is YES, the processing returns to the step 802 , and the same examination is performed on the another set of box information.
When it is determined that there is not any set of box information, the F-code entry of which agrees with the F-code which is the target of the search, after the contents of the sets of box information of all the already-opened boxes are examined, and the result of the determination of the step 806 is NO, or the result of the determination of the step 805 is NO, the all box searching processing is finished in error. That is, in this case, ‘failure’ is returned as the result of the search.
Thus, in this case where sets of box information each such as that shown in FIG. 25 are used, whether or not user authentication using the box information is allowed is set based on the code number allowance/rejection entry of the set of box information. Thereby, it is possible that the Group 3 facsimile apparatus can specify a user who cannot use this apparatus. Thus, user restriction can be performed more effectively.
In the above-described embodiment, the present invention is applied to a facsimile apparatus which uses PSTN as a transmission path therefor. However, it is also possible that the present invention is applied to a facsimile apparatus which uses ISDN as a transmission path therefor.
Further, the present invention is not limited to the above-described embodiment, and variations and modifications may be made without departing from the scope of the present invention.
The present application is based on Japanese priority application Nos. 11-179329 and 11-096093, filed on Jun. 25, 1999 and Apr. 2, 1999, respectively, the entire contents of which are hereby incorporated by reference. | A facsimile apparatus is provided with boxes corresponding to an F-code which is received by facsimile transmission procedures, executes a center-machine application using the corresponding boxes based on sub-address information when receiving image information, the apparatus comprising. In the apparatus, an F-code input requesting portion requests a user to input an F-code when the user operates the apparatus for performing transmission, and a control portion searches for the box for which an F-code is registered, the value of which F-code agrees with the value of the F-code input by the user, and, only when finding the box, agrees to accept the transmission operation performed by the user, and registers, in document managing information for managing the transmission job performed by the transmission operation, identification information for the box as authentication information. | 7 |
The present application is a reissue application for U.S. Pat. No. 4,069,210 issued Jan. 17, 1978. .Iaddend.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to polymeric products and, more particularly, relates to polymeric products which electrodeposit on the cathode.
2. Brief Description of the Prior Art
Electrodeposition of aqueous organic coatings has risen to industrial prominence in recent years. The process has many advantages, including uniformity and completeness of coating, even on intricate shapes. Virtually any electroconductive substrate may be coated, although the process has been primarily employed to prime or one-coat ferrous metal substrates.
Particular interest has recently arisen in electrodepositable coatings which deposit on the cathode. Cathodically deposited coatings appear to have better corrosion resistance than anodically deposited coatings. In addition, during anionic electrodeposition, oxygen and metal ions are evolved at the anode which may discolor the depositing coating. At the cathode, however, only hydrogen is evolved which has no detrimental effect on the depositing coating.
For electrodeposition on the cathode, most coating systems are based on polymers containing cationic salt groups. One particularly interesting class of polymer are those containing quaternary ammonium salt groups derived from reacting polyepoxides, such as a polyglycidyl ether of a polyphenol with tertiary amine salts. An example of these types of resins is disclosed in U.S. Pat. No. 3,839,252 to Bosso and Wismer. These resins, for the most part, are prepared with mono-tertiary amine salts and diepoxides and have the charge groups located in the terminal portions of the polymer molecule. Although these particular polymers are eminently suited for use in cationic electrodeposition, currently being employed commercially in many industrial electrodeposition coating applications, they are limited in the charge content attainable. Higher molecular weight species also have higher equivalent weights and this limits the dispersibility of the polymer.
The present invention can be looked upon as an improvement on the resins disclosed in U.S. Pat. No. 3,839,252. In the present invention, the resins are internally ionized with the charge groups being positioned along the polymer chain not only in terminal positions but also in the middle portions of the polymer chain. Thus, high molecular weight products with relatively low equivalent weights can be prepared. The products of the invention are very dispersible, making them particularly attractive candidates for electrodeposition.
SUMMARY OF THE INVENTION
In accordance with the present invention, a polymeric reaction product and preferably a quaternary ammonium salt group-containing polymer is disclosed. The polymer comprises the reaction product of:
A. an organic polyepoxide,
B. a polyamine containing at least two tertiary amine groups, formed from reacting:
1. .[.a member selected from the class consisting of.]. an organic polyisocyanate, .[.an organic polycarboxylic acid, ester or anhydride, and mixtures thereof,.]. .Iadd.with .Iaddend.
2. an active hydrogen-containing tertiary amine in which the active hydrogens are selected from the class consisting of mercapto, hydroxyl, primary and secondary amine.
To form the quaternary ammonium salt group-containing polymer, the reaction product is acidified to provide salt groups along the polymer backbone.
In a preferred embodiment of the invention, the polymeric products are non-gelled, water-dispersible and electrodepositable on the cathode. In this embodiment, (1) and (2) react with one another to form a polyamine which is stable in water, that is, when the final polymeric product is dispersed in water, the linkages which form between the reaction of (1) and (2) will not cleave the polymeric chain.
Besides polymeric products, the invention also contemplates the use of the preferred polymeric products in cationic electrodeposition.
PERTINENT PRIOR ART
U.S. Pat. No. 3,663,389 to Koral et al discloses resinous products suitable for use in cationic electrodeposition comprising the reaction product of a polyepoxide with a polyamine such as tetraethylene pentamine. The resulting product is solubilized with acid to provide cationic groups in the resin. The teachings of this patent differ from the present invention in that, first of all, the cationic groups are tertiary amine salt groups rather than the quaternary ammonium salt groups. In addition, there is no teaching in the reference of amines which are at all remotely similar to those prepared in accordance with the present invention.
The aforementioned U.S. Pat. No. 3,839,252 to Bosso and Wismer discloses quaternary ammonium salt group-containing resins formed from reacting polyepoxides with tertiary amine salts. Although most of the tertiary amine salts are monofunctional, the patent does disclose amines having the following structural formula: ##STR1## where R is an alkyl radical and n is 1 to 3. Specifically disclosed is the salt of tris(dimethylaminoethyl)phenol. Such polyamines differ from those of the present claims in that they do not include a polyamine formed from reacting an organic polyisocyanate .[.or an organic polycarboxylic acid.]. with an active hydrogen-containing tertiary amine. As mentioned above, preparing the polyamines in this fashion gives a wide variety of amines which can be made. Reactants can be varied from a wide choice of readily available materials to provide products with a wide range of desirable properties.
U.S. Pat. No. 3,947,339 to Jerabek et al discloses cationic resins suitable for use in electrodeposition obtained from reacting polyepoxides with polyamines containing at least one secondary amine group and a primary amine group blocked by ketimine groups. The resultant resins are solubilized with acid to provide tertiary amine salt groups. An example of a suitable secondary amine which can be used is the diketimine of triethylene tetramine which, in addition to the blocked primary amine groups, contains two secondary amine groups. However, the products of this particular reference differ from those of the present invention in that they require tertiary amine salt groups for solubility rather than the quaternary ammonium salt groups of the present invention. In addition, there is no teaching in this patent of forming the polyamines in any manner analogous to that of the present invention.
DETAILED DESCRIPTION
The polyepoxides of the present invention are polymeric compounds having a 1,2-epoxy equivalency greater than 1.0, that is, the average number of 1,2-epoxy groups per molecule is greater than 1. The polyepoxide can be any of the well-known epoxides. Examples of these epoxides have been described in U.S. Pat. Nos. 2,467,171; 2,615,007; 2,716,123; 3,030,336; 3,053,855; and 3,075,999. Preferred class of polyepoxides are polyglycidyl ethers of polyphenols such as Bisphenol A. These may be prepared, for example, by etherification of a polyphenol with epichlorohydrin or dichlorohydrin in the presence of an alkali. The phenolic compound may be bis(4-hydroxyphenyl)2,2-propane; 4,4'-dihydroxybenzophenone; bis(4-hydroxyphenyl)1,1-ethane; bis(4-hydroxyphenyl)-1,1-isobutane; bis(4-hydroxy-tertiarybutyl-phenyl)2,2-propane; bis(2-hydroxynaphthyl)methane; 1,5-hydroxy-naphthalene or the like. Another useful class of polyepoxides are produced similarly from novolak resins or similar polyphenol resins.
Also suitable are similar polyglycidyl esters of polyhydric alcohols which may be derived from such polyhydric alcohols as ethylene glycol, diethylene glycol, triethlene glycol, 1,2-propylene glycol, 1,4-butylene glycol, 1,5-pentanediol, 1,2,6-hexanetriol, glycerol, bis(4-hydroxy -cyclohexyl)2,2-propane, and the like.
There can also be employed polyglycidyl ethers of polycarboxylic acids which are produced by the reaction of epichlorohydrin or a similar epoxy compound with an aliphatic or aromatic polycarboxylic acid, such as oxalic acid, succinic acid, glutaric acid, terephthalic acid, 2,6-naphthalene dicarboxylic acid, dimerized linoleic acid and the like. Examples are diglycidyl adipate and diglycidyl phthalate.
The organic polyepoxide as described above is reacted with a polyamine containing at least two tertiary amine groups. The polyamine in turn is formed from reacting an organic polyisocyanate, which is preferred, or an organic polycarboxylic acid, anhydride or ester and an active hydrogen-containing tertiary amine.
The organic polyisocyanate (including blocked isocyanates) which can be used in the instant invention can be an aliphatic or an aromatic polyisocyanate or mixture of the two. Organic diisocyanates are preferred although higher polyisocyanates can be used in combination with the diisocyanates and/or monoisocyanates. Where higher functional polyisocyanates are used, some monofunctional isocyanates should be present to reduce the average functionality and control the tendency of the resultant reaction product to gel. Examples of suitable higher polyisocyanates are 1,2,4-benzene triisocyanate and polymethylene poly(phenyl isocyanate). Examples of suitable monoisocyanates are cyclohexyl isocyanate, phenyl isocyanate and toluene isocyanate. Examples of suitable aromatic diisocyanates are 4,4'-diphenylmethane diisocyanate, 1,4-phenylene diisocyanate and toluene diisocyanate. Examples of suitable aliphatic diisocyanates are straight chain aliphatic diisocyanates such as 1,4-tetramethylene diisocyanate and 1,6-hexamethylene diisocyanate. Also, cycloaliphatic diisocyanates can be employed and examples include 1,4-cyclohexyl diisocyanate, isophorone diisocyanate and 4,4'-methylene-bis(cyclohexyl isocyanate).
Besides polyisocyanate compounds such as described above, NCO-containing oligomers and polymers (prepolymers) prepared from reacting organic polyisocyanates such as described above with active hydrogen-containing materials can also be employed. The activity of the hydrogen is determined according to the Zerewitinoff Test as described by Kohler in the Journal of the American Chemical Society, 49 3181 (1927).
Examples of suitable active hydrogen-containing compounds are polyamines, polymercapto-terminated derivatives, polyols and active hydrogen-containing compounds containing mixed substituents such as amino alcohols. Polyamines, polyols and amino alcohols are preferred because of the ease of reaction they exhibit with polyisocyanates. Polyols, polyamines and amino alcohols give no side reactions, give higher yields of urethane and urea product with no by-products. Also, with regard to polyols, there are a wide variety of materials which are commercially available.
The polyols can be either high or low molecular weight materials and can include diols, triols and higher alcohols. Although, for water-dispersible, non-gelled products, diols are preferred. If higher alcohols are used, they should be used in combination with diols and preferably monoalcohols.
In the practice of the present invention, higher molecular weight or polymeric polyols are preferred. These materials, when reacted with suitable polyisocyanates, form NCO-prepolymers which contribute extremely desirable electrocoating properties to the resultant resin. Such polymeric polyols should be predominantly linear, that is, the absence of trifunctional or higher functionality ingredients to avoid gelling of the resultant polymeric product. Preferably, the polyols should have a hydroxyl value of 200 or less, preferably within the range of 150-30. The most suitable polymeric polyols include polyalkylene ether polyols including thioethers, polyester polyols including polyhydroxy ester amides and hydroxyl-containing polycaprolactones.
Use of polyisocyanates and particularly NCO-prepolymers is preferred because they form hydrolytically stable linkages on reaction with active hydrogen-containing compounds. Also, the reaction product of an organic polyisocyanate, particularly an NCO-prepolymer, contributes very desirable physical and chemical properties to the resultant coating. For example, selection of the right NCO-prepolymer can result in electrodepositable compositions which have higher rupture voltages and throwpower and which have improved film forming properties.
.[.Besides organic polyisocyanates, polycarboxylic acids can also be used in the practice of the invention. The acid could be aliphatic, aromatic or mixtures of the two and can be saturated or unsaturated aliphatic or of a mixed type. Organic dicarboxylic acids are preferred, although higher polycarboxylic acids can be used in combination with organic dicarboxylic acids and/or organic monocarboxylic acids, for example, fatty acids such as linoleic acid and linolenic acid. Examples of suitable higher polycarboxylic acids are: trimellitic acid and tricarballylic acid. Examples of suitable saturated aliphatic dicarboxylic acids are those having from about 2 to 18 carbon atoms per molecule and include adipic acid, azelaic acid, sebacic acid, succinic acid, glutaric acid and the like. Examples of suitable unsaturated aliphatic dicarboxylic acids include maleic acid, fumaric acid, aconitic acid, mesaconic acid, citraconic acid and itaconic acid. Examples of suitable aromatic dicarboxylic acids are phthalic acid, isophthalic acid, and terephthalic acid..].
.[.Besides the carboxylic acids such as those mentioned above, corresponding esters, partial esters and anhydrides where formable can also be used in place of part or all the acids..].
The active hydrogen-containing tertiary amine which is reacted with the organic polyisocyanate or polycarboxylic acid as described above is depicted by the following structural formula: ##STR2## where R' and R" may be the same or different and are aliphatic radicals containing up to 6 carbon atoms. Preferably, R' and R" are alkyl radicals. R'" is an aliphatic radical containing at least one active hydrogen and an aliphatic group containing up to 6 carbon atoms. By the term "active hydrogen" is meant hydrogens attached to nitrogen, sulfur and oxygen and include primary and secondary amino hydrogen, mercapto hydrogen and hydroxyl hydrogen, with hydroxyl and amino hydrogen being preferred.
Examples of active hydrogen-containing tertiary amines are alkanolamines such as dimethylethanolamine, methyldiethanolamine, dimethylamino-2-propanol and di-n-propanolamine; thiolamines such as N,N-dimethyl-2-aminoethanethiol and N,N'-dimethyl-3-aminopropanethiol; tertiary amines such as dimethylaminopropylamine, diethylaminopropylamine and dimethylaminoethylamine.
Preferably, the active hydrogen-containing tertiary amine and the organic polyisocyanate .[.or organic polycarboxylic acid.]. are reacted with one another to form a product which is relatively stable in water, that is, when the final polymeric product is dispersed in water, the linkages which form between the reaction of the active hydrogen-containing tertiary amine and the organic polyisocyanate .[.or organic polycarboxylic acid.]. will not immediately break apart and cleave the polymeric chain.
The polyamine prepared as described above can be acidified to form the corresponding tertiary amine salt. A wide variety of acids can be used including inorganic acids such as boric acid, carbonic acid, hydrochloric acid, phosphoric acid; also, organic acids such as lactic acid, which is preferred, acetic acid, formic acid, propionic acid and butyric acid can be used.
The tertiary amine salt is then reacted with the organic polyepoxide under conditions to form a quaternary ammonium salt group-containing polymer in which the salt groups are located along and towards the middle portion of the polymer backbone. This is accomplished by the polyamine salt chain extending and increasing the molecular weight of the polyepoxides. It is through this chain extension that the ionic charges are positioned in the middle portions of the polymer backbone. In the reaction of the polyamine with the polyepoxide, reaction occurs with the oxirane ring to ring open the product forming a quaternary ammonium salt group and a hydroxyl group.
Besides forming the tertiary amine salt of the polyamine, and subsequently reacting the salt with the polyepoxide, the polyamine can be reacted with the polyepoxide first, in the presence of water, and the reaction product subsequently acidified.
The equivalent ratio of polyepoxide to polyamine will vary depending on the molecular weight of the product desired and the reactivity of the polyamine and the polyepoxide. For electrodeposition use, the equivalent ratios should be controlled so as to produce polymeric products which contain about 0.2 to about 0.9 and preferably from about 0.4 to about 0.6 milliequivalents of quaternary nitrogen per gram of resin. Lower than the recommended amount of milliequivalents per gram results in poor resin solubility and unacceptable film builds upon electrodeposition. Higher than the recommended amounts of milliequivalents per gram results in a resin which is too water-soluble for electrodeposition purposes.
Also, for electrodeposition use, the polymer should be water-dispersible and non-gelled and, of course, electrodepositable on the cathode. Essentially linear polymers are preferred. Therefore, both the polyepoxide and the polyamine are preferably difunctional.
The amine (or amine salt) and the polyepoxide are reacted by mixing the components, preferably in the presence of a controlled amount of water. The amount of water employed should be that amount which allows for smooth reaction of the amine with the epoxy groups but not sufficient to cause extremely slow reaction. Typically, water is employed on the basis of about 1.75 to about 20 percent by weight, based on total reaction mixture solids, preferably from about 2 percent to about 15 percent by weight based on total reaction solids.
The reaction temperature may be varied between the lowest temperature at which reaction proceeds reasonably, for example, at room temperature, to a maximum temperature of about 100° C. and 110° C.
A solvent is not necessary although one may be used to afford better control of the reaction. Aromatic hydrocarbons or glycol ethers are suitable solvents.
Aqueous compositions containing the resinous products of the invention are highly useful as coating compositions and can be applied by many conventional methods, such as dipping, brushing, etc. The aqueous compositions are, however, eminently suited for application by cationic electrodeposition.
For electrodeposition, the above-described resinous products are dispersed in water to about 1 to 30 percent by weight resin solids. The term "aqueous dispersion" as used within the context of the present invention is intended to cover 2-phase translucent, aqueous-resin systems, particularly those in which the aqueous phase forms the continuous phase and is also intended to cover homogeneous aqueous solutions which appear optically clear. The aqueous dispersions of the present invention have dispersed phases which have average particle size diameters of about 0.1 to 5 microns. The dispersed phase may be spherical or elongated in shape or actually invisible by microscopic investigation.
The products can be employed as such to electrodeposit clear films, but ordinarily they are used as a vehicle along with a pigment composition. The pigment composition used may be any conventional type, for example, iron oxides, lead oxides, strontium chromate, carbon black, titanium dioxide, talc, barium sulfate and the like, as well as combinations of these and similar pigments. Color pigments such as cadmium yellow, cadmium red, phthalocyanine blue, chromic yellow, toluidine red, hydrated iron oxide, and the like may also be included.
Dispersing or surface active agents are usually used with the pigments and should be of the non-ionic or cationic type or a combination of these types. The pigment and surface active agent are ground together in a portion of the vehicle to make a paste, and this is blended with a major portion of the vehicle to produce a coating composition. There may also be included in the coating compositions additives such as anti-oxidants, wetting agents, dryers, anti-foaming agents, suspending agents, and the like. It is often desirable to include small amounts of water-miscible organic solvents, which may be added to the resinous vehicle to aid in handling and processing. Examples of such solvents are glycol ethers.
It has been found in most instances that desirable coatings are obtained using pigmented compositions containing weight ratios of pigment to vehicle of about 1.5 to 1 or less and preferably less than about 1 to 1. If the composition has too high a pigment to vehicle ratio, the electrodeposited film may have poor flow characteristics.
Coating compositions of the present invention may optionally include a crosslinker or curing agent to give harder, more corrosion-resistant coatings. The preferred curing agents are capped isocyanate derivatives. As has been mentioned above, when the tertiary amine salt reacts with the epoxy moiety, a quaternary ammonium salt group and a hydroxyl group is formed. It is through this hydroxyl group that the isocyanate groups react to crosslink and cure the coating. The isocyanates should be blocked or capped so they will not react with the hydroxyl in the coating composition until the coated article is heated to a high enough temperature to unblock the blocked isocyanates and cure the coating.
Polyisocyanate curing agents can be used in two similar ways. The polyisocyanate can be fully capped, that is, no free isocyanate groups remain, and then added to the chain-extended quaternary ammonium salt group-containing polymer to form a two-component system. Alternately, the polyisocyanate can be partially capped, for example, half-capped diisocyanate so that one reactive isocyanate group remains. The partially capped isocyanate can then be reacted with the polyepoxide through the hydroxyl groups present under conditions which will not unblock the isocyanate. This reaction makes the capped isocyanate a part of the polymer molecule and a one-component system. When the resultant coated article is heated to a high temperature, the blocked isocyanate group will unblock to react with the unreacted hydroxyls and other polyepoxide molecules and cure the resultant coating.
In formulating the water-dispersed compositions, ordinary tap water may be employed. However, such water may contain relatively high levels of ions which, while not ordinarily rendering the process inoperative, may result in variations in the properties of the baths when used for electrodeposition. In such cases, it is often desirable to utilize deionized water from which the free ions have been removed, such as by passage through an ion exchange resin.
In the electrodeposition process employing the aqueous coating composition described above, the aqueous composition is placed in contact with an electrically conductive anode and an electrically conductive cathode with the surface to be coated being the cathode. Upon passage of electric current between the anode and the cathode, while in contact with a bath containing the coating composition, an adherent film of the coating composition is deposited on the cathode.
The conditions under which electrodeposition is carried out are, in general, similar to those used in electrodeposition of other types of coatings. The applied voltage may be varied greatly and can be, for example, as low as 1 volt or as high as several thousand volts, although typically between 50 volts and 500 volts are employed. The current density is usually between about 1.0 ampere and 15 amperes per square foot and tends to decrease during electrodeposition. The method of the invention is applicable to the coating of any electrically conductive substrate and especially metal such as steel, aluminum, copper and the like.
After deposition, the coating is usually baked at elevated temperatures by any convenient method such as in ovens or with banks of infrared heat lamps.
The invention will be described further in conjunction with several examples showing the method and practice of the invention. These examples, however, are not to be construed as limiting the invention to their details. All parts and percentages by weight are based upon non-volatile contents unless otherwise indicated.
EXAMPLE A
A polyamine containing two tertiary amine groups formed from reacting toluene diisocyanate, a polycaprolactone diol and dimethylethanolamine was formed from the following charge:
______________________________________Ingredient Parts by Weight______________________________________toluene diisocyanate(80/20 isomeric mixture) 174polycaprolactone diol (MW = 640).sup.1 265dimethylethanolamine 89______________________________________ .sup.1 Solid commercially by Union Carbide Corporation under the trade name PCP 0200 and believed to be epsiloncaprolactone ring opened with diethylene glycol.
The procedure for making the polyamine was to first make an NCO-prepolymer by reacting toluene diisocyanate with polycaprolactone diol and then capping the NCO-prepolymer with a dimethylethanolamine.
The polycaprolactone diol was charged to a reaction vessel containing the toluene diisocyanate. The temperature was held at 30°-35° C. for 1 hour followed by the addition of the dimethylethanolamine. The reaction mixture was permitted to exotherm for 1/2 hour and then cooled to room temperature.
EXAMPLE B
A polyamine containing two tertiary amine groups formed from reacting toluene diisocyanate, polypropylene glycol and dimethylethanolamine was formed from the following charge:
______________________________________Ingredient Parts by Weight______________________________________toluene diisocyanate(80/20 isomeric mixture) 174polypropylene glycol (MW = 625).sup.1 302dimethylethanolamine 89.1______________________________________ .sup.1 Sold commercially by Union Carbide Corporation under the trade nam PPG 625.
The procedure for making the polyamine was similar to that in Example A, that is, an NCO-prepolymer was first prepared by reacting the toluene diisocyanate with the polypropylene glycol and then capping the NCO-prepolymer with the dimethylethanolamine. The polypropylene glycol was charged to a reaction vessel containing the toluene diisocyanate. The temperature was held at 30° to 35° C. for about 1 hour, followed by the addition of the dimethylethanolamine. The mixture was permitted to exotherm for 1/2 hour and then cooled to room temperature.
EXAMPLE I
A non-gelled, internally ionized quaternary ammonium salt group-containing polymer which is suitable for use as a coating vehicle in cationic electrodeposition was prepared from the following charge:
______________________________________Ingredient Parts by Weight Solids______________________________________EPON 829.sup.1 461.22 442.54Bisphenol A 148.89 148.892-ethylhexyl half-cappedtoluene diisocyanate 331.4 314.87polyamine of Example A 297.55 297.55lactic acid (75 percent byweight aqueous solution) 66 49.5phenyl CELLOSOLVE.sup.2 112.8 --FOAM KILL 639.sup.3 6.3 --TEXANOL.sup.4 112.8 --deionized water 62.67 --______________________________________ .sup.1 Epoxy resin solution made from reacting epichlorohydrin and Bisphenol A, having an epoxy equivalent of approximately 193-203, commercially available from Shell Chemical Company. .sup.2 Phenyl CELLOSOLVE is ethylene glycol monophenyl ether. .sup.3 FOAM KILL 639 is a hydrocarbon oilcontaining diatomaceous earth surfactant. .sup.4 TEXANOL is 2,2,4trimethylpentanediol-1,3-monoisobutyrate.
The polymer was prepared by charging the EPON 829 and Bisphenol A to a suitable reaction vessel, heating to 160°-165° C. and permitting the reaction mixture to exotherm. The reaction was maintained at a temperature of 155°-160° C. for 1 hour and then cooled to 120° C., followed by the addition of the 2-ethylhexanol half-capped toluene diisocyanate. The reaction mixture was held for 1 hour at 120° C., followed by the addition of the phenyl CELLOSOLVE, FOAM KILL 639, and 62.8 parts by weight of the TEXANOL. The remainder of the TEXANOL was pre-mixed with the lactic acid solution, deionized water and the polyamine of Example A to form a reactive mixture for quaternizing the polymeric product previously prepared. This reactive quaternizing mixture was added to the reaction mixture over a 30-minute period to form a 78.35 percent solids dispersion of non-gelled, quaternary ammonium salt group-containing polymer in which the salt groups are located along and towards the middle portion of the polymer backbone. The polymer contained 0.4388 milliequivalents of quaternary ammonium salt groups per gram of polymer.
When tested for throwpower in a General Motors cell (10 percent solids bath, 14 inch immersion depth), the polymer showed a throwpower of 7 inches when electrodeposited at 200 volts for 2 minutes at a temperature of 25° C.
EXAMPLE II
A non-gelled, internally ionized quaternary ammonium salt group-containing polymer suitable for use as a coating vehicle in cationic electrodeposition was prepared from the following charge:
______________________________________Ingredient Parts by Weight Solids______________________________________EPON 829 461.22 442.54Bisphenol A 148.89 148.892-ethylhexyl half-cappedtoluene diisocyanate 331.44 314.87polyamine of Example B 354.75 319.28lactic acid (75 percent byweight aqueous solution) 66 49.5phenyl CELLOSOLVE 114.76 --FOAM KILL 639 6.3 --TEXANOL 114.76 --deionized water 63.75 --______________________________________
The polymer was prepared by charging the EPON 829 and Bisphenol A to a suitable reaction vessel, heating to 160°-165° C. and permitting the reaction mixture to exotherm. The reaction was maintained at 155°-160° C. for 1 hour and then cooled to 120° C., followed by the addition of the 2-ethylhexanol half-capped toluene diisocyanate. The reaction mixture was held for 1 hour at 120° C., followed by the addition of the phenyl CELLOSOLVE, FOAM KILL 639 and 62.8 parts by weight of the TEXANOL. The remainder of the TEXANOL was pre-mixed with the lactic acid solution, deionized water and the polyamine of Example B to form a reactive mixture for quaternizing the polymeric product previously prepared. This reactive quaternizing mixture was added over a 30-minute period to the reaction mixture to form a 76.73 percent solids dispersion of quaternary ammonium salt group-containing polymer in which the salt groups are located along and towards the middle portion of the polymer backbone. The polymer contained 0.4313 milliequivalents of quaternary ammonium salt groups per gram of polymer.
When tested for throwpower in a General Motors cell (10 percent solids bath, 14 inches immersion depth), the polymer showed a throwpower of 7 inches when electrodeposited at 200 volts for 2 minutes at a bath temperature of 25° C.
.[.EXAMPLE III.].
.[.A polyamine containing two tertiary amine groups was formed from reacting an organic polycarboxylic acid ester (dimethylazelate) with an active hydrogen-containing tertiary amine (dimethylaminepropylamine) in the following charge ratio:
______________________________________Charge Parts by Weight______________________________________dimethylazelate 216dimethylaminepropylamine 408.].______________________________________
.[.The reactants were charged to a reaction vessel and heated to reflux for about 2 days. The reaction mixture was cooled to 25° C. to form a solid. Cyclohexane was added to the reaction vessel to slurry the reaction product followed by filtering and reslurrying the retentate and filtering again. The retained reaction product was then dried, and was believed to have the following structure: ##STR3##
.[.The polyamine containing the two tertiary amine groups was then reacted with an organic polyepoxide to form an internally ionized quaternary ammonium salt group-containing polymer in the following charge ratio:
______________________________________Ingredient Parts by Weight______________________________________EPON 1004.sup.1 1000diamine prepared as described above 151.375 percent by weight aqueouslactic acid solution 100.8phenyl CELLOSOLVE 245.4deionized water 49______________________________________ .sup.1 Epoxy resin prepared from reacting epichlorohydrin and Bisphenol A having an epoxy equivalent of approximately 875-1000 commercially available from Shell Chemical Company.
.[.The EPON 1004 was charged to a reaction vessel and melted under a nitrogen blanket. Forty parts of the phenyl CELLOSOLVE was added followed by the addition of the diamine, lactic acid solution, remaining phenyl CELLOSOLVE and deionized water. One hundred parts by weight of methyl ethyl ketone was added to thin the reaction mixture. The reaction mixture was held at 85°-95° C. for 1 hour. Nine hundred eighty-five parts by weight of the reaction mixture was poured into a can and then thinned with 15 parts by weight of warm deionized water. An additional 100 parts by weight of butyl CELLOSOLVE (monobutyl ether of ethylene glycol) was added..].
.[.An electrodeposition bath was formed by further thinning the reaction-mixture with 1100 parts by weight of deionized water. The bath was filtered and cooled. When tested for throwpower in a GM cell (22 percent solids bath, 17 inches immersion depth), the polymer showed a throwpower of 8 inches when electrodeposited at 400 volts for 2 minutes at a bath temperature of 27° C..]. | Polymeric products comprising the acidified reaction product of an organic polyepoxide and a polyamine containing at least two tertiary amine groups are disclosed. The polyamine and the organic polyepoxide are reacted with one another under conditions to form an internally ionized, quaternary ammonium salt group-containing polymer which has a high molecular weight, but relatively low equivalent weight. The polyamine is formed by reacting an organic polyisocyanate .[.or organic polycarboxylic acid.]. with an active hydrogen-containing tertiary amine. The reaction product is acidified to form the quaternary ammonium salt groups. Preparing the polyamine in this manner gives one wide latitude in determining the final structure of the polyamine. In effect, one can "tailor make" the polyamine by appropriate selection of reactants and exert a great measure of control over the properties of the final polymeric product. The preferred polymeric products are non-gelled, water-dispersible and electrodepositable on the cathode. .Iadd. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of identification technology, as is used for security and data storage media systems, for example. It relates particularly to a system and a method for producing user media in an identification system.
2. Description of Related Art
Identification systems (often the term “authentication system” would be more correct) are used for different applications such as access control (in what are known as ‘online’ systems, in which an object for which access is being controlled is in contact with a central unit, and in ‘offline’ systems, in which this is not the case), prepaid card systems, data acquisition systems, etc.
Usually, the identification systems have user media—for example “Smart Cards”—which are provided with a data memory which stores a suitable electronic key. In application, data interchange takes place—usually without physical contact—with a read and/or write device, wherein the electronic key is used to perform an authentication process and the desired action—for example the release of an object, the purchase of an item or service, the writing of a piece of information to the user medium, etc.—is performed successfully only if the electronic key is established to be correct in the read and/or write device or possibly in the user medium, or the result of a computation operation on the basis of the key produces a desired value.
A frequently chosen approach is for the common electronic key to be stored on all user media and for the electronic key to be known to all read and/or write devices in a system. This is a good solution for small, straightforward systems. However, it makes no sense in larger systems, for if a medium or the key is lost and (possibly) reaches an unauthorized person, all elements of the system need to be reprogrammed with a new key.
An alternative approach is to provide what is known as a “Site Key” or “Master Key” which is used as a basis for calculating the electronic keys. The electronic keys for the various media differ from each other, only the ‘Master Key’ is common. The ‘Master Key’ is never used for identification, and it cannot be calculated from the keys.
This alternative approach makes it possible such that not all elements of the system to have to be reprogrammed in the event of loss of a medium, but rather only particular applications which are affected by the loss. However, some significant drawbacks remain as user media are generally initialized, and have information written to them, by a computer which must contain the master key. This is a security risk because the whole system is endangered if the master key is copied. For this reason, media in such systems are issued by central certification offices—for example provided by the vendor of the entire identification system—and these central certification offices never issue the master key. Although satisfactory security devices at the central certification offices warrant the required security to a certain extent, the procurement of new media is complicated and—as a result of the involvement of the central certification office—also expensive. Furthermore, there is always the residual risk of abuse by persons working at the certification office.
A system with a central certification office for applications in the banking sector or the like is described in U.S. Pat. Nos. 4,811,393 and 4,910,773, for example. In accordance with this teaching, ‘User Cards’ (user media) are provided which are also in the form of security modules whose memory can be accessed only by the dedicated module processor, for example. The user media are used to store a derived key (diversified key) which has been determined from a base key. This system also requires a central certification office and is furthermore also costly because all user media need to be designed in hardware as security modules with appropriate processors and data memories.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to provide approaches which remedy this situation.
The present case provides an identification system comprising at least one key dispenser medium with a first integrated circuit and at least one user medium. The first integrated circuit comprises memory means and processor means which are preferably monolithically integrated. It is equipped to store a source key (“Site Key”) and to calculate keys derived therefrom, wherein the hardware of the key dispenser medium preferably does not allow the unencrypted source key to be read. The user medium may have a second integrated circuit and is equipped to store a derived key and to perform an authentication process on the basis of this derived key together with a read and/or write device.
The monolithic integration of the first integrated circuit, which, besides the memory for the source key, also contains the processor means for calculating the derived key, is advantageous in that no data allowing calculation of the source key need to leave the integrated circuit in order to calculate the derived key.
According to a first property of preferred embodiments of the invention, the read and/or write device has a third integrated circuit, which, like the key dispenser medium, is equipped to store a source key (“Site Key”) and to calculate keys derived therefrom.
In this case, the hardware of the read and/or write device preferably does not allow the unencrypted source key to be read and, for example, also does not allow encrypted data comprising the source key to be issued, and/or, for example, also does not allow derived keys to be issued. The latter are calculated exclusively in order to perform the authentication process together with the user media, which of course also comprises this derived key. However, provision may also be made for the third integrated circuit to forward the derived key to another element of the read and/or write device, which then, for its part, performs the authentication process with the user medium.
With particular preference, the third integrated circuit is of physically identical design to the first integrated circuit and differs therefrom only in that it is configured differently.
In line with a second property of preferred embodiments of the invention, the key dispenser medium and the user medium are now of physically different design such that the user medium is able to read the source key or ascertain it in another way neither directly nor using means (for example an interposed computer) and/or that the user medium is unable to calculate a derived key.
By way of example, the first integrated circuit and the second integrated circuit may be designed with such different hardware that the first integrated circuit is able to perform operations (calculations etc.) which the second integrated circuit is not at all able to perform.
This approach has the important advantage that holders of user media cannot turn them into a key dispenser, not even by means of illegal actions. The key dispensers can be kept in a small number and inspected at any time.
In some embodiments of the invention, the identification system has at least two different communication channels which are fundamentally distinguished by the physics of the signal transmission and/or by the protocols used. Thus, by way of example, provision may be made for the key dispenser media to be able to be read exclusively in a contact-based fashion, while the communication between user media and read and/or write device is effected contactlessly, for example by means of radio frequency waves (RFID) or other electromagnetic waves, inductively or capacitively/resistively. The use of electromagnetic waves for the data interchange both with the key dispenser media and with the user media, but using different frequencies and/or different protocols, is also conceivable.
Preferably, identification systems based on these embodiments are designed such that user media have different data interchange interfaces than the key dispensers, i.e. the different communication channels mean that the user media cannot read data which are sent by key dispenser media on at least one available communication channel.
The approach in line with these embodiments enhances advantages which are obtained on the basis of the second advantageous property.
In line with a third property of preferred embodiments of the invention, the key dispenser medium is capable of decrypting and storing an encrypted source key provided by another key dispenser medium, and of encrypting the source key for forwarding to another key dispenser medium. This allows the key dispenser medium to duplicate a key dispenser (in this case a ‘Key Dispenser’ refers to a key dispenser medium with a source key stored thereon) onto a ‘Blank’ key dispenser medium.
In the approach based on the third property, the source key is issued only in encrypted form and, by way of example, only after a further security element, for example a PIN, has been input. Alternatively or in addition, the further security element required may be the forwarding of a (for example encrypted) specific code (uniqueness number of the like) for the key dispenser medium that is to have information written to it. By way of example, this specific code is requested at the start of the process by the key dispenser medium that is to have information written to it. This additional security feature has the advantage that an abusively stored data packet with the encrypted source key cannot also be used to generate further key dispensers. The security feature may be required for all first processor means and possibly also for the third processor means, for example provided that they can have information written to them online, or else only for a selection of processor means.
For the purpose of the encryption, the key dispenser media may be provided, during manufacture, with a security key which is not known to the operator of the identification system (a separate security key may be provided for each operator, or the security key may be identical for a plurality of operators or even for each operator without security problems arising therefrom). The security key is used for decrypting—and in the case of symmetrical encryption, also for encrypting—the source key and is integrated in the first integrated circuit such that it can never be issued. As an alternative, it is also possible for asymmetric encryption to be provided, wherein at least the key required for decryption is a security key which is known only to the security chip.
For example, provision may be made—such an approach is known per se—for the security key not to be known to a single individual, but rather for it to be obtained from a combination of different key elements which are known to different persons/groups of persons.
With particular preference, the source key can be generated by the key dispenser medium itself.
All in all, the opportunity arises for an operator of the identification system to initialize the user media himself and to provide them with (derived) keys without having them produced by a central unit with appropriate security devices. Nevertheless, security is not adversely effected in comparison with existing systems, which will be explained in more detail in the description which follows. The user is also able to generate and manage a plurality of key dispenser media, which is advantageous when one of the media fails or is lost.
In line with one preferred refinement of embodiments with the third property, there may be two different types of key dispenser media. A first type of key dispenser media is capable of producing further key dispensers by means of duplication. Although a second type of key dispenser media—also called “reduced key dispenser medium” in this text—is able to derive derived keys from the source key—and possibly to initialize read and/or write devices as described below—it is unable to produce any other key dispensers.
In line with a first variant, this is accomplished by providing data produced by the first/second type of key dispenser medium with different designations. The integrated circuits of both types of key dispenser media disallow the storage of a source key if the data contained (in encrypted form) in the source key come from a reduced key dispenser medium. This can be prompted by appropriate configuration of the first integrated circuit.
In line with a second variant, the second type of key dispenser media is totally incapable of issuing the source key (in encrypted form).
The distinction between the first and second key dispensers allows finer gradation of authorizations by the operator.
The use of reduced key dispensers in line with the first variant is furthermore appropriate particularly when the encrypted source key is sent via a data line or a network, as described below. In that case, a person intercepting the data line without authorization is unable to generate a key dispenser from the encrypted source key even if a key dispenser medium blank is present.
In embodiments of the invention with a fourth advantageous property, an identification system can be set up such that the operator of the system is able to generate keys for daily use on user media himself. There are, thus, two mutually independent instances which contribute to producing the keys in use:
the manufacturer of the identification system who provides the media (key dispenser media/user media/read and/or write devices), with security features therein, and the operator himself, who can generate the keys used entirely independently of the manufacturer.
In comparison with the prior art, this is more secure, since even a group of persons working for the manufacturer can never obtain all security features, since the keys themselves are produced by the operator. Furthermore, the approach is also less complex and sometimes less costly for the operator, since he is able to set up the entire system himself and also reconfigure it again if adjustments are necessary.
In embodiments with the fourth property, the operator is issued a set of parts, for example, which comprises at least one key dispenser medium—which preferably has the ability to generate the source key itself and is delivered as a key dispenser medium blank—and a plurality of user media, likewise without a key (or with a temporary key which is set up at the factory). The set preferably also includes an instruction which explains how the operator himself can generate source keys, derive derived keys therefrom and possibly duplicate key dispensers.
While each of the above advantageous properties can be implemented on its own on an identification system according to the invention, combinations of the above advantageous properties, which synergistically contribute together to increased security, to compatibility with existing identification technologies and to ease of handling by the operator, are particularly preferred, as can be seen more specifically from the explanations which follow and from the description of the exemplary embodiments. Arbitrary combinations of two, three or all four of the advantageous properties are part of the teaching according to the invention; quite particular preference is given to a combination of all four properties.
The statements which follow can—unless indicated otherwise—be applied to all properties and combinations of properties.
The key dispensers contain the source key and are set up to calculate a derived key from the source key and further parameters (for example a uniqueness number and/or an application index) and to issue said derived key. The key dispensers are provided as ‘Masters’ only to a restricted circle of users, for example only to a system responsibility holder. Furthermore, the key dispensers—or the first integrated circuits thereon—may be set up such that they make the issue of the encrypted source key and/or the issue of a derived key dependent on the input of an identification code (for example PIN). If an improper code is input multiple times, there may be provision for an automatic “reset”, for example including the source key being deleted or rendered inaccessible. The first integrated circuits are monolithic in the sense that memory means and processor means are integrated in a common chip, and there are no data lines between the memory and the processor which are accessible without destroying the chip.
The first—and possibly also the third integrated circuit—may be in the form of a security chip, for example, which has both the memory means and the processor means. Security chips which output (certain) data only in encrypted form and which also render ‘Reverse Engineering’ at least more difficult are already known in principle. The first and possibly the third integrated circuits additionally have means, for example, on the basis of the source key and use further data (for example a uniqueness number and/or an application index) to calculate a derived key. Furthermore, the first integrated circuit can issue this derived key—possibly in encrypted form.
The key dispenser media may physically be in the form of chip cards, dongles, chip sets which are or can be integrated into a data processing appliance (slot etc.), etc. The physical form is not significant to the invention, and the monolithic integration of the memory containing the source key with the processor means which encrypt the latter and calculate the derived keys in a single chip is preferred in all cases.
The second media are user media. They contain a derived key calculated by a key dispenser. They are furthermore equipped to interchange data with a read and/or write device on a—preferably contactless—route and to perform an authentication process. By way of example, the data interchange between user media and a read and/or write device can be effected using radio frequency (RF) signals. In this case, an inherently known technology can be used, at the time of writing the present text for example Mifare® (a system based on ISO 14443A which is offered in different variants, including “Mifare Classic” and “Mifare DESfire”), or else FeliCa (ISO 18092), another system based on ISO 14443A, a system based on ISO 14443B, etc. In principle, it is possible to use any technology which allows the authentication of user media and of a read and/or write device using contactless or else contact-based data transmission. As is also explained in more detail below, an advantage of the identification system according to the invention is that a good security standard is provided which is independent of the built-in securities of the data transmission technology. The method steps which take place during the authentication are usually defined by the technology used (for example “Mifare Classic”). They may be based on the challenge-response method or on other approaches and are in some cases proprietary and not known; the invention works regardless of whether the authentication is performed using known or secret algorithms. The approach according to the invention merely provides the—derived—key; the way in which this is used for the authentication is of no significance to the invention.
The physical form of the user media may be any form which is known from the prior art, for example as a chip card (with an RFID chip—in this form also called an RFID ‘Tag’—or other chip), as an RFID tag integrated in another medium (clock, mobile telephone, etc.), as a chip incorporated into a key, etc. New, alternative forms are also conceivable.
For the authentication, the read and/or write devices are the counterpart of the user media. The third integrated circuit is possibly able to calculate the possibly specific application key of the user medium, for example initially from parameters provided by the user medium (for example the uniqueness number and/or the application index). To this end, the third integrated circuit is then set up, for example like the first integrated circuit, to perform a calculation from the source key and these parameters using the same algorithm—for example a hash algorithm—as the first integrated circuit. The third integrated circuit is also preferably monolithic in the sense that memory means and processing means are integrated in a common chip, and there are no data lines between memory and processor which are accessible without destroying the chip. The third integrated circuit may have the physical design of the first integrated circuit, but the configuration is preferably chosen such that issue of the source key even in encrypted form is not possible, or that a key issued by a third integrated circuit is not adopted by a first or third integrated circuit.
The read and/or write devices may outwardly be designed like known read and/or write devices (for example from Mifare applications), wherein, in contrast to the known read and/or write devices, said third integrated circuit is present, which calculates the key required for the authentication.
The approach in accordance with the various embodiments of the invention has the following advantages: the ‘Secret’ of the identification system is the source key. The hardware of all elements in the system is set up such that the source key is not issued by any component of the system in unencrypted form. The source key may have been stored only by a first or possibly a third integrated circuit, and only a first or third integrated circuit is able to store the source key (system-external media are totally unable to decrypt the key, even if it is available to them in encrypted form). The first and third integrated circuits may be in the form of chips, for example security chips, produced/configured specifically for the application. This, in turn, allows the third integrated circuits to be configured such that they do not issue the source key or a derived key under any circumstances, not even in encrypted form. It is thus possible to use the design of the first and possibly third integrated circuit to ensure that only the key dispenser media can act as key dispensers, and only the key dispenser media can generate further key dispenser media by forwarding the encrypted source key.
As a result, the forwarding of the source key and the production of derived keys can be controlled perfectly. Only someone who is physically in possession of a key dispenser medium is able to generate applications keys and possibly create further key dispenser media—regardless of the design of the second media, and what means (computer with Smart Card Reader (RFID write module, etc.) are used to write information thereto.
The key dispenser medium is not needed in the everyday operation of the identification system, however, and can be stored securely and in seclusion, for example in a safe (physical security).
Provided that the source key can be generated by the operator, it does not need to be known to the manufacturer (system provider). The security key is known at most to the manufacturer, and by way of example to nobody. The security chips used can be produced only by the manufacturer. All in all, a very secure system is obtained which provides good protection against abuse.
BRIEF DESCRIPTION OF THE DRAWINGS
Properties and exemplary embodiments of the invention are discussed below with reference to schematic figures, in which:
FIG. 1 shows a scheme for the initialization of components of an embodiment of an identification system according to the invention;
FIG. 2 shows a scheme for the interchange of information in the embodiment shown in FIG. 1 during daily operation;
FIGS. 3 a - 3 e show possible physical forms of a key dispenser medium;
FIG. 4 shows a form of a user medium;
FIGS. 5 a and 5 b show elements of various embodiments of a read and/or write unit;
FIG. 6 shows a form of an auxiliary medium for transferring the source key to an offline read and/or write unit; and
FIG. 7 shows a schematic illustration of components of an identification system according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 schematically show components of an identification system according to the invention. These components may be physically in the form of chips or ‘Tags’ of the type mentioned above, or may have such chips. In addition to the outlined data memory means and data processing means, there are generally further means which prompt the actual data interchange, for example antennas, amplifier means (which apply a signal to an antenna) etc., or else contact areas, etc. Since the precise form of these further means is not relevant to the invention, it is not discussed further at this juncture.
As FIG. 1 shows, a key dispenser medium 1 holds a source key 11 and a security key 12 . The security key 12 is used to encrypt the source key; it can never be read from the key dispenser medium. The source key is stored in a writeable, for example nonvolatile, memory of the key dispenser medium. The internal wiring of the key dispenser medium does not allow the source key 11 to be read off externally, and the wiring and/or the firmware of the key dispenser medium does not allow the source key 11 to be issued without encryption. Besides means for encrypting the source key 11 with the security key 12 , the key dispenser medium has further data processing means 14 for calculating a derived key 13 from the source key and further parameters 15 , such as the uniqueness number and/or an application number, etc.
Besides a (preferably writeable, non-volatile) memory 15 with a uniqueness number, application number and/or other, for example application-dependent, data, the user medium 12 also has a memory location for a derived key. The user medium may be designed and configured in the manner of inherently known user media from identification systems, for example, and the relevant data processing means, for example for encrypting data with the derived key, may also be implanted.
In a similar manner to the key dispenser medium, the electronics module of the read and/or write device 3 has a security key 12 and memory locations for the source key 11 and also data processing means 14 for calculating a derived key 13 on the basis of the source key 11 and further parameters 15 such as the uniqueness number and/or an application number, etc. Before the identification system is initialized, the user is provided with at least one key dispenser medium 1 (preferably a plurality of key dispenser media) and a plurality of second media 2 , and read and/or write devices are provided with third integrated circuits. The key dispenser media and the third integrated circuits are already provided with the security key; the security key is not disclosed to the user. All media and all read and/or write devices are in a basic state, in which they have no source or derived keys, for example, apart from possible temporary keys which are prescribed during manufacture and which cannot ensure the entire security.
The initialization of the identification system may involve the following method steps taking place:
First of all, upon initialization by the user, the source key 11 can be ascertained in a key dispenser medium, for example as a random number, for example having at least 64 bits, preferably at least 128 bits, particularly preferably at least 256 bits. This turns the medium into a key dispenser (master).
The key dispenser (the initialized key dispenser medium) can then optionally be duplicated by writing to a further key dispenser medium. It is advantageous if the user has at least one duplicate of the key dispenser so that it can continue to operate and service the identification system in the event of a key dispenser being lost or faulty.
In the case of the duplication process too, the source key never leaves the key dispenser medium in unencrypted form, but rather in a form encrypted with the security key 12 . The target medium 1 ′ onto which the key dispenser is duplicated likewise has the security key 12 and can decrypt the security key 12 and store it in the provided memory.
The key dispenser 1 can also be used to initialize the read and/or write device 3 with the third integrated circuit. For this purpose, as FIG. 1 shows, the source key 11 is likewise read into the memory provided for this purpose. In the presence of the key dispenser, the read and/or write device can also be programmed with regard to functions, access or entry rights, etc., by a programming appliance which is provided for this purpose.
The issue of the source keys by the master may be linked to a further security element, for example the input of a PIN. For this purpose, the key dispenser medium and also the read and/or write device may have means for reading in such a PIN (or the like) which have been input by the user using a suitable input means—for example a computer, via which the key dispenser medium is connected by means of card reader or interface, or a programming appliance which can contact a read and/or write device contactlessly—or have been read in by suitable means; this also includes the possibility of requesting biometric data.
A user medium 2 is initialized by calculating the derived key 13 using the parameters 15 —which have been provided by the user medium 2 beforehand, for example—in the key dispenser medium 1 . Subsequent to the calculation, the derived key 13 is stored in the memory location provided for this purpose in the user medium.
In use, as FIG. 2 shows, a communication link is set up between the user medium and the electronics module 3 of the read and/or write device. First of all, the user medium-specific parameters 15 are transmitted to the third integrated circuit 3 , as a result of which the latter is capable of calculating the derived key 13 from the source key 11 and these parameters 15 . The derived key does not need to be stored permanently (even if permanent storage of the derived key is an option), but rather can be calculated afresh for every data interchange with a user medium.
As soon as the user medium 2 and the third integrated circuit of the read and/or write device 3 are in possession of the (identical) derived key 13 , the authentication process can take place, and read and/or write processes can take place on the memory means of the user medium 1 and/or on the memory means of the read and/or write device. The data interchange taking place during the authentication process—said data interchange may be based on the challenge-response principle or on another principle—can be performed in a manner which is known per se from the prior art. By way of example, it is possible for a known, proprietary or standardized protocol to be used. One of the strengths of the invention is that the security features and practical advantages of the approach according to the invention are independent of the protocols used for the authentication and for the data interchange and that it is therefore possible to use any suitable protocols. Sometimes, the persons with the user medium 2 do not need to be aware at all that the identification system differs from the art (for example “Mifare Classic”) by virtue of additional security features.
FIGS. 3 a to 6 show possible physical forms of and media and electronics modules from the components of identification systems according to the invention. However, the implementation of a system according to the invention is not dependent on the components used. It is possible to use media/modules which are in a form other than the media/modules shown; FIGS. 3 a to 6 merely show a few possible examples.
The key dispenser medium 1 shown in FIG. 3 a is in the form of a “Smart Card” (chip card) 31 with a chip 32 . The chip 32 is a security chip of the type mentioned which incorporates both memory means and processor means in a monolithic design. The data interchange described above is effected using a, by way of example, conventional chip card reader. By way of example, such a chip card reader may be connected to a computer which performs the data interchange. On the basis of the approach in accordance with various embodiments of the invention, a source key 11 will at no time be located in unencrypted form in a data memory of the computer. The computer may have an RFID reader and writer connected to it at the same time as the chip card reader, which means that the data interchange shown in FIG. 1 between the key dispenser medium 1 and the user medium 2 can be performed directly, online. However, it is also conceivable for the data interchange to be performed with a time offset, by calculating and reading a plurality of derived keys 13 , for example, together with the parameters 15 into the computer and subsequently initializing a plurality of user media.
The chip card 31 shown in FIG. 3 b , which can likewise be used as a key dispenser medium, differs from that shown in FIG. 3 a in that it has a radio frequency antenna 33 in a direct communication link to the chip 32 . When the chip 32 is supplied with current, it can use this antenna to interchange data directly with an RFID medium, for example with a user medium 2 in the form of an RFID chip or with an offline read and/or write unit, the (for example only) communication interface of which is an RFID communication interface.
The chip card shown in FIG. 3 c also has, in addition to the chip 32 , an RFID chip 34 with an RFID antenna 35 . This RFID chip 34 can have the encrypted source key 11 written to it online (while the chip card is connected to a computer for the purpose of communication), for example. Said RFID chip then transmits the encrypted source key 11 to an offline read and/or write unit, the (for example only) communication interface of which is an RFID communication interface. The functionality of the chip card 31 shown in FIG. 3 c is thus very similar to that shown in FIG. 3 b.
FIG. 3 d shows the key dispenser medium 1 as a USB dongle 36 . The dongle incorporates the security chip, which may be physically identical to the chip 32 of the chip cards. The functionality of the key dispenser medium shown in FIG. 3 d is identical to that of the key dispenser medium shown in FIG. 3 a , but with no chip card reader being required. Instead of a USB interface, such a dongle may naturally also have another interface.
FIG. 3 e shows a security chip 32 which is mounted directly on a printed circuit board 37 and is contact-connected by the latter, such a printed circuit board possibly being in the form of a plug-in card for a computer, for example. It is also conceivable for the security chip 32 to be mounted onto an already existing board in a computer.
An identification system in accordance with the invention may have only key dispenser media 1 which are in the same form, or any combinations are conceivable. However, it is preferred for the security chip to be of respectively identical design and functionality even in the case of different media, that is to say for the different media to differ only in terms of how the data interchange with the chip takes place.
FIG. 4 shows a possible user medium 2 . This is in the form of a chip card 41 with an RFID chip 42 having an RFID antenna 43 . Instead of on a chip card, the RFID chip and the RFID antenna may also be on another support, for example integrated in an appliance with yet other functions (mobile telephone, clock, etc.), on a chip card cover, etc.
FIG. 5 a schematically shows an electronics module for a read and/or write device 3 . In addition to a chip 52 , which is in the form of a security chip such as that of a key dispenser medium (but, as mentioned, with a slightly different configuration), and an RFID antenna 53 for the data interchange with a user medium, the read and/or write device 3 also has an interface 54 for the data interchange with a control center. The read and/or write device shown in FIG. 5 a is accordingly an example of a read and/or write device which is suitable for an ‘online’ read and/or write device which can be initialized and programmed form the control center. At least for the initialization, and preferably also for the programming, the control center will have a key dispenser medium which is connected to a computer in the control center for the purpose of communication, for example. For the initialization, the encrypted source key is sent to the chip 52 via data lines and via the interface 54 , for example.
The read and/or write device 3 from FIG. 5 b differs from that in FIG. 5 a in that there is no interface. The read and/or write device is suitable for an ‘offline’ read and/or write device and needs to be initialized and possibly programmed by means of RFID data interchange, for example using an appropriate RFID programming appliance with a chip card reader in conjunction with a key dispenser medium as shown in FIG. 3 a , or using a key dispenser medium as shown in FIG. 3 b or 3 c . As a further alternative, an auxiliary medium can be used for this purpose, as is described below.
FIG. 6 shows an auxiliary medium 61 which may physically be in a form such as a user medium and does not necessarily differ therefrom. The auxiliary medium 61 is used for transmitting a (encrypted) source key 11 to an ‘offline’ read and/or write device and at the outside—depending on the configuration of the identification system and security demands for the programming of the read and/or write devices—also for the authentication to such an identification system for programming the read and/or write device. By way of example, such an auxiliary medium 61 can have information written to it by a computer which is connected to a key dispenser medium for the purpose of communication.
For all the media described, it is true that other communication channels can be used instead of or in addition to RFID technology, for example infrared, Bluetooth or other contactless interfaces, contact-based signal transmission, the capacitive-resistive coupling, etc.
FIG. 7 is also used to show elements of a possible form of an identification system in accordance with the invention and to explain a few steps relating to the operation thereof. A control center, for example equipped with at least one suitable computer 72 , of the operator of the identification system receives from the manufacturer at least one key dispenser medium 1 and, by way of example, at least one reduced key dispenser medium 71 . Suitable means—in this case a chip card reader 73 connected to the computer—can be used to start the initialization process in a key dispenser medium and to produce a source key. The key dispenser medium provided with the source key in this manner becomes the first key dispenser. The computer, which can buffer-store the source key provided by the first key dispenser and encrypted with the preinstalled security key and can transmit it to other key dispenser media, is possibly used to produce further key dispensers and, by way of example, also to provide a reduced key dispenser medium with the source key. The presence of the encrypted source key in a computer buffer store is not a security risk, since it can be decrypted only by the key dispenser media and by the read and/or write devices. Preferably, the key dispenser media are additionally set up such that they issue the encrypted source key and possibly also derived keys only after a PIN has been input; if an incorrect PIN has been input multiple times, a key dispenser medium is automatically reset to the basic state, and the source key is deleted or rendered inaccessible. In addition or as an alternative, the data packet stored on the computer with the encrypted source key may also additionally have the—for example encrypted—uniqueness number of the key dispenser medium that is to have information written to it, and the key dispenser medium can have information written to it only in the event of consistency.
The first key dispenser or one of the further produced key dispensers or reduced key dispensers subsequently generates derived keys for the user media 2 . For this purpose, either the uniqueness number and/or application number is read from the user media already provided therewith—this is done using an RFID read and write unit 74 , which is likewise connected to the computer—or the application number and/or possibly also the uniqueness number is generated by the computer and is loaded onto the user media only during the initialization process. It is also possible for a plurality of application numbers with a respective derived key to be stored on a medium so that the user medium can perform a plurality of functions.
The derived key is read from the key dispenser by the computer and—possibly together with the application number and/or possibly the uniqueness number—loaded onto the integrated circuit (for example RFID chip) of the relevant user medium.
At the same time, beforehand or afterwards, the read and/or write devices are initialized. As examples of read and/or write devices, FIG. 7 schematically shows a security door 76 connected to the control center via a data line online, a data collection terminal 77 which is likewise connected to the control center online, a second security door, which can be contacted via the internet 81 and is located in a different building/building complex than the control center, a (“offline”) door 79 which cannot be programmed via data lines from the control center, and a chip card reader 84 , which in this case likewise cannot be contacted from the control center using data lines and which is connected to a computer 83 .
For the initialization, the source keys are transmitted (in encrypted form) to the read and/or write devices via data lines (for 76 - 78 ) or (for 79 and 84 ) via an auxiliary medium 61 , an RFID-compatible key dispenser, using an RFID-compatible chip card reader or via a suitable other interface of the read and/or write device. At the same time or subsequently, they are programmed by allocating appropriate authorizations (on the basis of application number and/or uniqueness number, on the basis of time, etc.), for example. The programming can be done online using the relevant data lines (for 76 - 78 ) or (for 79 and possibly 84 ) using a programming appliance 80 . The read and/or write devices can also be reprogrammed at a later time at any time, a possible prerequisite for the reprogramming being the presence of a key dispenser and/or the input of security features (programming PIN etc.); in the former case, the read and/or write device requests the source key before it changes to a programming mode, for example. Instead of or at the same time as reprogramming, it is naturally also possible for data stored in the read and/or write device to be requested.
The PC 83 with chip card reader 84 is an example of the use of the invention for controlling access to a virtual entry point for a computer or computer network. In this case, the security chip may be in the chip card reader or in the computer (network) and authorize the access to the computer (network) as a whole or for particular applications; it goes without saying that it is also possible for the control center to be programmed via data lines, as in the case of the ‘online’ applications described above.
Following the initialization, the key dispensers—which are preferably all registered—are stored at a secure location, for example in a safe which is accessible only to a restricted group of people. If a key dispenser goes astray or there is another security gap, the read and/or write devices and the available (or recently delivered) key dispenser media are put into the basic state and reinitialized without the need for components to be interchanged. A prerequisite for the resetting of the read and/or write devices to the basic state is preferably the presence of at least one working key dispenser, i.e. so long as there is still one working key dispenser, reinitialization is possible at any time.
In addition to the read and/or write devices shown in FIG. 7 , there may also be other read and/or write devices, for example with other functions, such as appliances for deregistering or loading the user media as value cards, etc. A special category of read and/or write devices are devices which do not have a third integrated circuit, therefore do not know the source key and are, for example, provided with a fixed application key. The security for transactions with such read and/or write devices is not as high, since manipulation by an unauthorized party can barely be controlled once the application key has been copied. Provision is therefore preferably made for special read and/or write devices of this kind to be able to be used only in secured spaces and/or for them to be able to read data only and the user media which do not allow the writing of data from such read and/or write devices. One possible application of such special read and/or write devices is time recording.
In line with one possible variant for the approach described above, the source key can, upon issue, also be encrypted asymmetrically instead of symmetrically with the security key. In that case, at least the decrypting key should be proprietary and known only to the first and third integrated circuits. Preferably, however, the encrypting key is also proprietary and known only to the relevant circuits so that an ‘incorrect’ key dispenser would be recognized if reprogramming of the read and/or write devices were attempted.
As a further variant, the process of duplicating a master can also take place via a data line at the same time. | An identification system includes at least one user medium, which is equipped to store a derived key and authenticate itself using the same with respect to a write and/or read device. Furthermore, at least one key dispensing medium is present, which comprises a monolithic first integrated circuit having storage means and processor means, wherein the first integrated circuit is equipped to store a source key and derive therefrom the derived key and to pass it on for storage in the user medium, wherein the user medium is enabled neither directly nor by way of aids to read the source key from the key dispensing medium and/or the user medium is not enabled to calculate a derived key. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a surface mountable light emitting device, particularly, a surface mountable light emitting device having a high power capacity.
Conventional light emitting diodes provide a light emitting semiconductor chip within a metal cup, a lead wire to a further contact on the chip, a bullet lens over the structure and a body around the structure. Often the body would be formed integrally with the bullet lens. Both the cup and the lead wire are attached to legs extending from an underside of the body for connection through a printed circuit board into a suitable circuit.
The manufacture of products that utilize large numbers of light emitting diodes may favor the use of surface mountable devices. The attachment of many such LEDs to, for example, a printed circuit board holding the driving circuitry can be achieved considerably more economically by automated machines. If such a machine can operate on a single side of the printed circuit board to place and secure the LED, significant savings may be made, and the reverse side of the printed circuit board can be left free for the provision of the driving circuitry. All of this requires a surface mountable device that avoids the traditional placement of the legs of the LED through a printed circuit board and soldering on the reverse side of the board.
A variety of methods have been attempted to achieve a suitable surface mountable light emitting device. Usually, such methods have involved the protrusion of the lead wire and a connection to the lead frame at the side of the device for attachment to the surface on which it is to be mounted. Although surface mountable, such connections are arranged around a perimeter of the device, which limits the density at which they may be mounted on the surface.
A further problem with light emitting devices occurs more permanently with high power devices. An LED running at high power, such as at one watt generates a significant amount of heat. This heat can deteriorate the performance of the LED or, over time, lead to the destruction or burn out of the LED.
Although the heat may be dissipated by the surrounding apparatus, this still requires the transfer of the heat from the source, to outside of the LED. The legs extending from the body of the LED provide a relatively small thermal pathway, and do not allow sufficient heat dissipation to allow high power units on the order of one watt.
A yet further difficulty in the subject art arises in the manufacture of LEDs. It is difficult to provide a process that allows easy manufacture of LEDs with a minimum of components while assuring the requirements, e.g., greater heat dissipation, of high power units are met.
Also, conventional LEDs are optically unsuitable for direct installation into devices such as headlamps or flashlights that use parabolic reflectors. This is because the bullet lenses used form a narrow beam that completely misses a nearby parabolic reflecting surface. Using, instead, a hemispherically emitting non-directional dome, centered on a luminous LED die, gives a maximum spread commercially available, a Lambertian pattern. Since θ for a typical parabolic flashlight reflector extends from 45° to 135°, an LED with a hemispheric pattern is still mismatched with respect to a parabolic reflector because the LED's emission falls to zero at only θ=90°. This results in a beam that is brightest on the outside edges and completely dark halfway in to its center. Worse yet, even this inferior beam pattern from a hemispheric LED requires that the LED be held up at the parabola's focal point, several millimeters above the socket wherein a conventional incandescent bulb would be installed.
There is thus a need in the art for an effective and optically suitable surface mountable light emitting device (LED) that avoids the traditional placement of the legs of the LED through a printed circuit board and soldering on the reverse side of the printed circuit board, provides sufficient heat dissipation, allows easy manufacture with minimum components, ensures the requirements of high power usage are met, and is optically suitable for direct installation into devices that use parabolic reflectors as replacements for tungsten filament light bulbs.
SUMMARY OF THE INVENTION
The present invention advantageously addresses the needs above as well as other needs by providing a surface mountable light emitting device that avoids the traditional placement of legs of the LED through a printed circuit board, and soldering of the legs to the printed circuit board on the reverse side of the printed circuit board, provides sufficient heat dissipation, allows easy manufacture with minimum components, ensures the requirements of high power usage are met, and is optically suitable for direct installation into devices that use parabolic reflectors and replacement of tungsten filament light bulbs.
In one embodiment, the invention can be characterized as a high power, surface mountable light emitting device comprising a light emitting semiconductor chip, a thermally and electrically conductive lead frame connected to said chip and exposed over a substantial portion of the underside of the device, a lead wire from said chip to a contact exposed at least partially on a side of said device and a lens over said chip.
The lens comprises a lower transfer section and an upper ejector section situated upon the lower transfer section. The lower transfer section is operable for placement upon the light emitting semiconductor chip and operable to transfer the radiant emission to said upper ejector section. The upper ejector section is shaped such that the emission is redistributed externally into a substantial solid angle.
A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description of the invention and accompanying drawings, which set forth an illustrative embodiment in which the principles of the invention are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
FIG. 1 is a side cross-sectional view of an optical device according to an embodiment of the present invention;
FIGS. 2A through 2F are side cross-sectional, top perspective, bottom perspective, side, top planar, and side elevational views, respectively, of the lens of the optical device of FIG. 1 according to an embodiment of the present invention;
FIGS. 3A and 3B are side perspective and bottom planar views, respectively, of the optical device of FIG. 1;
FIG. 3C is a side perspective view of an optical device according to an alternative embodiment of the present invention;
FIG. 4A is a side perspective view of an optical device according to an alternative embodiment of the present invention;
FIG. 4B is a bottom planar view of the device of FIG. 4A;
FIG. 5A is a schematic of a driving circuit of an optical device according to an embodiment of the present invention;
FIG. 5B is a schematic of a driving circuit of an optical device according to an alternative embodiment of the present invention;
FIG. 5C is a schematic of a driving circuit of an optical device according to an alternative embodiment of the present invention utilizing an integrated circuit;
FIG. 6 is a side cross-sectional view of a light bulb integrating the device of FIG. 1 according to an embodiment of the present invention; and
FIG. 7 is a partial side cross-sectional view of an optical device according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the presently contemplated best mode of practicing the invention is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
Referring to FIG. 1, shown is a side cross-sectional view of an optical device according to an embodiment of the present invention.
Shown is a light emitting device 1 having a main body portion 2 according to that described in Hong Kong patent application No. 03104219.4 filed Jun. 12, 2003 for A SURFACE MOUNTABLE LIGHT EMITTING DEVICE AND METHOD OF MANUFACTURE, the entirety of which is hereby incorporated by reference, and lens 10 according to that described in U.S. patent application Ser. No. 60/470,691 of Minano et al., for OPTICAL DEVICE FOR LED-BASED LIGHT-BULB SUBSTITUTE, filed May 13, 2003, and U.S. patent application Ser. No. 10/461,557 of Minano et al., for OPTICAL DEVICE FOR LED-BASED LIGHT-BULB SUBSTITUTE, filed Jun. 12, 2003, the entirety of which is also hereby incorporated by reference. The main body portion 2 has a lead frame 3 , a further contact 4 , an LED semiconductor chip 6 , electrical connection 7 , and portions of a transparent optical molded compound 8 , 9 . A lens 10 comprises a lower transfer section 11 , an upper ejector section 12 and a conical indentation 13 .
The lead frame 3 is located in the main body portion 2 . The LED semiconductor chip 6 is mounted on the lead frame 3 . A further contact 4 to provide the path for current through the chip 6 is also provided and attached to the semiconductor chip 6 by an electrical connection 7 such as a lead bonding wire. Preferably the LED semiconductor chip is a single bond pad LED, but may also be a double bond pad LED (which would require an additional cathode bonding wire). The lens 10 is provided over an upper surface to encapsulate the semiconductor chip 6 and provide preferred optical characteristics.
As also shown in this particular embodiment, the lens 5 and the main body portion 2 may be provided in a single molding step as integrally molded portions from the same material using a transparent optical molded compound. lternatively, the lens 10 may attach to the device 1 using optical grade glue. To act as a lens, material used to form the lens 10 should be substantially transparent, although not necessarily completely transparent as there may be some desire to adapt the optical characteristics of the output of the semiconductor chip with the lens 10 . The molding of the lens 10 and the main body portion 2 in a single integral structure allows the transparent optical molded compound to be keyed into the lead frame 3 and further contact 4 by the portions of the transparent optical molded compound 8 and 9 . This helps secure the lead frame 3 and further contact 4 in place in the final device with minimal need for adherence between the transparent optical molded compound and the metal of the lead frame 3 and the further contact 4 .
The semiconductor chip 6 is recessed into a recess within the lead frame 3 such that the sides of the recess act as a reflector. The purpose of such a reflector around the semiconductor chip 6 is to redirect light that may be emitted from the sides of the semiconductor and reflect the light generally out through the transparent optical molded compound 5 upwardly from the semiconductor chip 6 .
Example applications include, but are not limited to, replacement of incandescent lights or other luminaire light sources that are non-directional and pointed like an LED, replacement of a flashlight bulbs, use as exterior and interior automotive lights, use in miniature industrial light bulbs, and any other lighting applications that require use of a pseudo filament to mimic traditional luminaries. This may include, for example, marine control panels or dashboard lights, avionic cockpit panel lights and other interior lighting that utilizes miniature light bulbs.
Referring next to FIGS. 2A through 2F, shown are side cross-sectional, top perspective, bottom perspective, side, top planar, and side elevational views, respectively, of the lens 10 of the optical device 1 of FIG. 1 according to an embodiment of the present invention.
Shown are the lens 10 , lower transfer section 11 , upper ejector section 12 and conical indentation 13 .
The lens 10 comprises a lower transfer section 11 and an upper ejector section 12 . The lens 10 is a substantially transparent solid in the general shape of a prolate ellipsoid and is a single piece of a transparent optical molded material such as acrylic or polycarbonate. The lens 10 is preferably a rotationally symmetric shape, larger in height than in diameter, but need not be so (e.g., a free form shape). The upper ejector section 12 is cylindrical, with a conical indentation 13 on top, having a core angle of approximately 80°.
The lower transfer section 11 uses internal reflection to relocate the device's 1 emission upward to a parabola's focal point. The upper ejector section sends the transferred light out (to a parabolic reflector, for example), sideways and downward at angles to the axis extending all the way to at least 135°, or a little more, (measured relative to a central axis of the ejector section, back toward the semiconductor chip 6 ) depending upon the reflector. At least half the ejected light should be at angles over 45° (measured relative to a central axis of the ejector section back toward the semiconductor chip 6 ), in order to illuminate a reflector (not shown) and form a sufficiently intense collimated beam.
In order to avoid an external reflective coating on the surface of the transfer section 11 , its geometry must promote total internal reflection. This is why polycarbonate, with its higher refractive index (1.5855), is preferable to acrylic (1.492). Its correspondingly smaller critical angle, θc=sin− 1 (1/n), of 39.°103 vs. 42.°1, reduces the height of the transfer section from 23.5 mm to 11.6 mm.
Referring next to FIGS. 3A and 3B, shown are side perspective and bottom planar views, respectively, of the optical device of FIG. 1 .
Shown are the light emitting device 1 , the main body portion 2 , the lead frame 3 , the further contacts 4 , the lens 10 , the lower transfer section 11 , the upper ejector section 12 and the conical indentation 13 .
The further contact 4 can be seen exposed on the side of the main body portion 2 . It can also be seen in FIG. 3B that the lead frame 3 is exposed over a substantial portion of the underside of the device 1 . This exposure of a large surface area of the lead frame 3 on the underside of the light emitting device 1 allows substantial heat to be drawn directly from the lead frame 3 into a surface on which the lead frame 3 may be mounted.
Referring next to FIG. 3C shown is a side perspective view of an optical device 1 according to an alternative embodiment of the present invention. Shown is the light emitting device 1 , main body portion 2 , further contact 4 and lens 16 comprised of an off-axis ellipsoidal transfer section 17 and a spherical, diffusive ejector section 18 according to that described in U.S. patent application Ser. No. 60/470,691 of Minano et al., for OPTICAL DEVICE FOR LED-BASED LIGHT-BULB SUBSTITUTE, filed May 13, 2003, and U.S. patent application Ser. No. 10/461,557 of Minano et al., for OPTICAL DEVICE FOR LED-BASED LIGHT-BULB SUBSTITUTE, filed Jun. 12, 2003.
The outer surface of the ejector section 18 has diffusive characteristics, (i.e. surface features that cause light to diffuse), so that each point on the ejector section 18 has a brightness proportional to the light received from the transfer section 17 . The advantage of this kind of ejector section 18 is that the multiple wavelengths, for example, from a tricolor LED are mixed before they leave the ejector section 18 . In the non-diffusive ejector section 12 discussed above, which is non-diffusive, the color mixing may be incomplete, leading to coloration of the output beam of a parabolic reflector. The lens 16 comprises an off-axis ellipsoidal lower section 17 and an upper spherical ejector section 18 . The upper spherical ejector section 18 is smaller than the transfer section 17 (i.e., having a smaller diameter than a middle diameter of the transfer section 17 ). Due to the smaller upper spherical ejector section's size it radiates less in angles beyond 90° than if the upper spherical ejector section 18 were larger than the transfer section 17 . Such a upper spherical ejector section will also act to mix the colors of the red, green, and blue source chips within an LED light source.
Referring next to FIGS. 4A and 4B, shown are a side perspective and bottom planar views, respectively of an optical device according to an alternative embodiment of the present invention.
Shown is the light emitting device 19 , the main body portion 2 , the lead frame 3 , the further contacts 4 , the LED components 21 , 22 , 23 and the lenses 10 .
A plurality of individual LED components 21 , 22 , 23 are incorporated into a single device 19 as shown. Each individual LED component of the device 19 is structured and operates in the same way as that of FIG. 1 . This embodiment may be utilized where a plurality of LEDs are necessary to provide a desired output from a device and rather than utilizing three single LEDs fitted individually. The surface mountable nature of the device 19 may provide advantages in placement of all LED components on a suitable substrate and driving mechanism such as a printed circuit board (PCB) while still co-joined.
Naturally, it will be further appreciated that the number of individual LEDs within the device 19 as shown in FIGS. 4A and 4B can be 2 , 3 or any other number such as shown by way of example in FIG. 1 of Hong Kong patent application No. 03104219.4 filed Jun. 12, 2003 for A SURFACE MOUNTABLE LIGHT EMITTING DEVICE AND METHOD OF MANUFACTURE which has been incorporated by reference.
A yet further advantage of the embodiment as shown in FIGS. 4A and 4B is that different colored LEDs can be provided. For example, during the manufacturing process, a different chip may be fitted to each individual LED component 21 , 22 and 23 . This may allow, for example, a red, blue and green color arrangement through the use of a different color chip in each of the individual LED components 21 , 22 and 23 so as to provide a full video color spectrum or the like. It will be appreciated that a variety of other color schemes are possible.
Referring next to FIG. 5A, shown is a schematic of a driving circuit of an optical device 6 according to an embodiment of the present invention.
Shown is a DC/DC step-up converter 25 having a coil 26 , a resistor 27 , a transistor 28 , a diode 29 , a capacitor 30 and an LED 6 .
The step up converter (from 1V to 4V) uses +1 VDC to +3 VDC to drive the device 6 up to 70 Ma. The coil 26 and the transistor 28 are used as a switching regulator and the resistor 27 is used as a current control. The diode 29 provides a rectifier and the capacitor provides a ripple filter. In this case, a single 1.5V battery is utilized to drive the LED 6 .
Referring next to FIG. 5B, shown is a schematic of a driving circuit of an optical device 6 according to an alternative embodiment of the present invention.
Shown is a light emitting device 1 , an LED 6 , a photo sensor 31 , a resistor 32 , a transistor 33 and a resistor 34 .
The light emitting device 1 (in this case a surface mountable diode package) circuit comprises a photo sensor 31 in die form and the LED 6 to which a resistor 32 , a transistor 33 and a resistor 34 are connected. This allows for the LED 6 to activate based upon varying light levels detected by the photo sensor.
Referring next to FIG. 5C, shown is a schematic of a driving circuit of an optical device according to an alternative embodiment of the present invention utilizing an integrated circuit.
Shown is a light emitting device 1 , an LED 6 and an integrated circuit control die 35 . The integrated circuit control die 35 is operably between the LED 6 and a power source, such as a 1.5 V DC power source, to control operation of the LED 6 . The integrated circuit control die 35 provides control, for example, for the LED 6 to flash or blink in a pattern.
Referring next to FIG. 6, shown is a side cross-sectional view of a light bulb, integrating the device of FIG. 1 into a light bulb housing, according to an embodiment of the present invention.
Shown is a light bulb 36 having the light emitting device 1 of FIG. 1 with the lens 10 , the printed circuit board (PCB) 37 , an E10 lamp base 38 , the wires 39 to the lamp base 38 and anode 40 , an epoxy seal 41 and a glass encasement 42 .
The light emitting device 1 , which acts as the optical filament of the light bulb 36 , is operably connected to the printed circuit board 37 secured at the top of the lamp base 38 . Two wires 39 are operably connected each to the lamp base 38 and anode 40 to provide power to the light emitting device 1 . The lens 10 has the inverted cone feature shown in, for example, FIG. 1 and is located inside the glass encasement 42 of the light bulb 36 . The epoxy seal 41 is between the glass encasement 42 and the lamp base 38 . The light emitting device 1 may also be used in applications such as exterior and interior automotive lights, wherein circuitry is provided in the printed circuit board to draw off a 2 amp current to drive the flasher circuit of the automobile (or whatever amount of current happens to required for the particular application).
Referring next to FIG. 7, shown is a partial side cross-sectional view of an optical device according to an alternative embodiment of the present invention.
Shown is a light emitting device 1 having a main body portion 2 . The main body portion 2 is a variant of that of FIG. 1 in that it incorporates three semiconductor chips 6 , 45 , 47 in one surface mountable light emitting device 1 . The light emitting device 1 has a lead frame 3 , a further contact 4 , electrical connections 7 , 46 , 48 , and portions of a compound 8 , 9 . A lower transfer section 11 of the lens 10 of FIG. 1 is also partially shown.
The lead frame 3 is located in the main body portion 2 . A plurality (three in this case) of semiconductor chips 6 , 45 , 47 are mounted on the lead frame 3 . A further contact 4 to provide the path for current through the chip 6 is also provided and attached to the semiconductor chips 6 , 45 , 47 by electrical connections 7 , 46 , 48 such as a lead bonding wires. Preferably the semiconductor chips are single bond pad LEDs, but may also be a double bond pad LEDs (which would require an additional cathode bonding wire). The lens 10 (partially shown) is provided over an upper surface to encapsulate the chips 6 , 45 , 47 and provide preferred optical characteristics.
As also shown in this particular embodiment, the lens 5 and the main body portion 2 may be provided in a single molding step as integrally molded portions from the same material using a transparent optical molded compound. Alternatively, the lens 10 may attach to the device 1 using optical grade glue. To act as a lens, the material should be substantially transparent although not necessarily completely transparent as there may be some desire to adapt the optical characteristics of the output of the semiconductor chip with the lens. The semiconductor chips 6 , 45 , 47 are recessed into recesses within the lead frame such that sides of the recesses act as reflectors.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
All references cited herein are herein incorporated by reference. | This invention relates to a surface mountable light emitting device in which the lead frame is exposed over a substantial portion of the underside of the device so as to allow greater thermal conductivity to any device on which it may be mounted. The LED provides the lens and a molded body to encapsulate the lead frame and an electrical contact in a single molding step while the lead frames and further contacts are arranged in a suitable array. The lens couples the luminous output of a light-emitting diode (LED) to a predominantly spherical pattern comprises a transfer section that receives the LED's light within it and an ejector atop it that receives light from the transfer section and spreads it spherically. Applications may include, but are not limited to, household light bulbs and car headlights. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a latch assembly for securely coupling one connector member to a mating connector member, and relates more particularly to an electrical connector including a latch assembly for securely coupling electrical connector mating members together in an easily releasable manner.
[0003] 2. Brief Description of Prior Developments
[0004] Various types of electrical connector structures comprising two mating parts held together by a latching assembly are known. However, many of the known latching mechanisms have various disadvantages. A traditional latch, for example, is formed of a separate attached lever that pivots on a fulcrum in a cantilevered fashion. This type of system has limited holding strength because the separating direction and force causing separation will naturally pivot the lever back to an open position thereby decreasing the overall holding strength. When linking cables end to end, it is desirable to employ a latching assembly that will prevent the connector members from separating under normal conditions of strain. It is also desirable to employ a latching assembly that is uncomplicated to use and one that does not require special tooling to activate.
[0005] Examples of some of the prior developments in latch assembly technology are described in the following U.S. patents:
[0006] U.S. Pat. No. 5,167,523 describes an electrical computer cable connector that has high strength and resistance to twisting forces including a housing and latching arms located along lateral sides of the housing. The latching arms have engaging ends for engaging a complementary electrical connector, actuator ends for finger grasping to move the engaging ends of the latching arms about a pivot point, and spring arms to give a spring action to the latching arms. The latching arms are formed of relatively thick gauge metal to prevent bending or deformation of the engaging ends, and resist separation forces of at least 50 pounds. A housing cover fits over the housing and latching arms.
[0007] U.S. Pat. No. 5,486,117 describes a locking system for an electrical connector assembly which includes first and second electrical connectors. The first connector includes a housing having a mating face and a latching surface facing in a direction generally opposite the mating face. The second connector includes a housing having a complementary mating face for interfacing with the mating face of the first connector and a metal spring latch arm cantilevered from the second connector, with a hook portion for latchingly engaging the latching surface of the first connector. The latch arm is located for manual deflection to move the hook portion out of engagement with the latching surface to allow unmating of the connectors with minimal force. The hook portion is radiused therefore deflecting the latch arm in response to an unmating force applied directly to the connectors, i.e. without manual deflection of the latch arm, that is greater than the minimal force.
[0008] U.S. Pat. No. 5,564,939 describes a plug-in connector including a connector main body having contacts connected to a cable, and a housing accommodating the connector main body. Latch springs are respectively attached to first and second surfaces of the housing, and respectively have first engagement portions which engage, in a locked state, second engagement portions of a jack connector to be connected with the plug-in connector. An operating member, which cooperates with the latch springs, includes latch releasing portions respectively engaging with the latch springs and disengaging the latch springs from the second engagement portions when the plug-in connector is pulled whereby the plug-in connector is released from the locked state.
[0009] The invention in U.S. Pat. No. 5,569,047 is directed to an improved squeeze-to-release latching mechanism for a pair of intermatable transmission connectors. The connectors comprise a plug consisting of a housing having top and bottom surfaces, where such housing supports a first transmission component, and a receptacle supporting a second transmission component, where the plug includes a pair of cantilevered flexible arms engagable with complementary latching projections on the receptable. The arms have exposed intermediate portions manually movable toward one another, such as by squeezing, to disengage the latching projections from the flexible arms. The flexible arms may be grasped diagonally and moved toward another to effect an unmating of the plug from the receptacle.
[0010] U.S. Pat. No. 5,762,513 describes an electrical connector assembly including a header, a housing matable with a header, a termination cover retained on the housing, and a wiring strain relief, with housing, cover and strain relief securable as a unit to header. Latches include a latch arm on the strain relief extending past the termination cover and engaging and latching to the header and further include overstress stops movable to engage surfaces on the strain relief and resist further pivoting movement of the latch arms.
[0011] U.S. Pat. No. 5,775,931 describes a latching system for mating electrical connectors including a guide ferrule provided on a shell of a first connector for receiving an appropriate guide post on the mating electrical connector. A latch member pivotally mounted on the guide ferrule includes a latch end latchingly engageable with a groove in the guide post. A housing of resilient dielectric material is overmolded about portions of the shell and includes an integral spring portion for biasing the latch member in its latch position.
[0012] U.S. Pat. No. 5,853,297 describes a system and method for the multi-contact co-planar edge-to-edge electrical connection of printed circuit boards (PCB) that embodies an electrical connection between the printed circuit boards and a rigid latching physical connection between the printed circuit boards. A latching mechanism on the second PCB cooperates with a shaped mating end of a first PCB whereby the second PCB slides onto and latches with the first PCB. Cantilever beam springs on either side of the second PCB permits the two PCB's to positively engage one another to form a stable rigid connection of the two PCB's.
[0013] U.S. Pat. No. 5,941,726 describes a connector including a connector subassembly with a pair of covers secured thereover extending from a mating face to a cable exit to define a strain relief section extending along a portion of the cable. A pair of latch members is secured in the connector, each in a respective channel defined in the covers along opposite sides. Actuating sections protrude rearwardly along a strain relief section and are deflectable theretoward during actuation to release latching sections from a mating connector for unmating. Protuberances of the actuating sections are received into recesses of the strain relief section, for transmitting rearwardly directed unmating force from the latch members to the strain relief section of the covers.
SUMMARY OF THE INVENTION
[0014] In accordance with one embodiment of the present invention a latch assembly for coupling first and second connectors which are adapted to be held together in a contiguous relation to one another comprises at least one latching arm having upper and lower portions. The arm extends from the second connector towards the first connector and has a catch on its upper portion adapted to engage the first connector and retain the first connector and the second together. Included is a fulcrum mechanism adapted to allow each latching arm to pivot on the assembly in a manner such that when a sufficient inward force is applied to the lower portion of each latching arm below the fulcrum, the upper portion of the arm deflects in an outward direction to allow unmating of the first and second connectors.
[0015] In accordance with another embodiment of the present invention an electrical connector is adapted to be secured to a second electrical connector. The connector includes a conductive element secured to a housing for engaging a corresponding conductive element on the second connector and a latch assembly for securely coupling the connector to the second electrical connector. The latch assembly includes at least one elongated latching arm having upper and lower portions, the arm extending from the housing and having a catch mechanism on the upper portion adapted to engage the second connector and to securely position the connector to the second connector. The latch assembly also include a fulcrum mechanism adapted to allow each elongated latching arm to pivot thereon in a manner whereby when a sufficient force is applied to the lower portion of each latching arm below the fulcrum, the upper portion of the arm and the catch mechanism deflects in an outward direction thereby allowing unmating of the connector and the second connector.
[0016] In accordance with yet another embodiment of the present invention an electrical connector assembly comprises first and second electrical connectors adapted to be secured together. The connector assembly includes a conductive element secured to a housing of the first connector for engaging a corresponding conductive element on a housing of the mating second member, and a latch assembly for securely coupling the first and second electrical connectors to one another. The latch assembly includes two elongated latching arms, each arm having upper and lower portions, the arms extending from the second connector housing to the first connector and having a catch mechanism on the upper portion adapted to engage the first connector and securely position the first connector to the second connector. The latch assembly also includes a fulcrum mechanism adapted to allow each elongated latching arm to pivot thereon in a manner whereby when a sufficient force is applied to the lower portion of each latching arm below the fulcrum, the upper portion of each arm and the catch mechanism deflect in an outward direction thereby allowing unmating of the first and second conductors.
[0017] In accordance with the features of the present invention, a resistance feature has been added to the structure of a latch mechanism such that the overall holding strength of the latch assembly design is only limited by the material strength of the material forming the latch assembly structure. When linking cables with a latch assembly such as electrical cables end to end, the latching assembly according to the features of the present invention will not permit the connectors to separate under conditions of normal strain. In addition other advantages of the latch assembly according to the features of the present invention include the fact that the latch assembly is uncomplicated to use and does not require special tooling to be activated. In accordance with the specific features of the present invention with one beam structure two discrete actions that benefit both engagement and separation in a latching assembly are now made available.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
[0019] FIGS. 1 - 5 illustrate plan views of two connector members and a latching arm for securely connecting the two members during the steps of engagement and separation in accordance with the features of the present invention;
[0020] FIGS. 6 - 7 are perspective views of a first electrical connector structure employing latching assembly features in accordance wit the present invention;
[0021] FIGS. 8 - 9 are perspective views of a second electrical connector structure employing latching assembly features in accordance with the present invention;
[0022] [0022]FIG. 10 is a perspective view of a third electrical connector structure employing latching assembly features in accordance with the present invention;
[0023] [0023]FIG. 11 is a cross sectional plan view of an electrical connector illustrating the embodiment of the present invention therein the fulcrum members are a unitary part of the latching arms and a connector member; and
[0024] [0024]FIG. 12 is a cross sectional plan view of a connector in accordance with the features of the present invention wherein the fulcrum members are an integral part of the connector member, and the latching arms are separate members from the connector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Although the present invention will be described with reference to the embodiments shown in the drawings, it should be understood that the present invention can be embodied in many alternate forms of different embodiments. In addition, any suitable size, shape or type of elements or materials could be used.
[0026] The connector system described herein was developed primarily for electrical connectors and therefore will be described in that context. However, the invention is believed to have utility for many other types of interconnections wherein connectors must be latched securely together and easily released.
[0027] FIGS. 1 - 5 illustrate in a simplistic format how the latching assembly in accordance with the features of the present invention functions. In the embodiment illustrated, first connecting member 11 , such as an electrical connector, is being moved in the direction of arrow 12 such that it will eventually mate with second connecting member 13 , such as an electrical connector, so that the two members 11 and 13 will be positioned in a contiguous relation. In the embodiment illustrated, latching arm 14 includes an upper and lower portion 15 and 16 respectively, and extends from and may be a unitary part of secondary connecting member 13 . Positioned at the end of the upper portion 15 of latching arm 14 is a catch mechanism or latch pawl 17 . Also included is a fulcrum member 18 which is illustrated in this particular embodiment as a fulcrum extending from the body of the second connecting member 13 towards latching arm 14 . However, in accordance with a further embodiment of the present invention the fulcrum member 18 could extend from the latching arm 14 toward the secondary connecting member 13 (see FIG. 5).
[0028] As illustrated in FIG. 2 as the first connecting member 11 continues to be moved in the direction of arrow 12 it will impact with the catch mechanism (latch pawl) 17 of latching arm 14 in such a way that latching arm will be deflected in the direction of arrow 19 thereby permitting the second connecting member 13 to eventually meet with and be held in contiguous relation to first connecting member 11 . When first connecting member 11 mates with second connecting member 13 , the catch mechanism 17 and the upper portion 15 of latching arm 14 will lock the first connecting member 11 to the second connecting member 13 (See FIG. 3). Once fully engaged the latch arm 14 returns to its free position, thereby trapping the inserted connector in mated condition with the other connector. By simply applying a force in the direction of arrow 20 to the lower portion 16 of latching arm 14 (see FIG. 4) the latching arm 14 will be forced against fulcrum member 18 resulting in the upper portion 15 of latching arm 14 being deflected outwardly in the direction of arrow 19 so as to release the holding grip by the catch mechanism 17 of first connector member 11 to second connector member 13 . First connector member 11 is now thereby free to move in the direction of arrow 21 .
[0029] The fulcrum member 18 in accordance with the features of the present invention can be either attached to the connector body 13 as illustrated in FIGS. 1 - 4 or the latching arm 14 as illustrated in FIG. 5, and function in accordance with the features of the present invention. Furthermore, in accordance with the features of the present invention, the latching arm 14 can be molded from plastic material and be a unitary part of the connector member or, stamped from metal and be a separate structure. The critical aspect of the design in accordance with the features of the present invention is that with a single latching arm, two discrete actions that benefit the feature of engagement and separation are available in a latching mechanism for two connecting members.
[0030] There is illustrated in FIGS. 6 and 7, and 8 - 10 , two different embodiments of electrical cable assemblies which can employ the latching assembly in accordance with the features of the present invention. The embodiments connect two electrical connectors in the same manner as illustrated in FIGS. 1 - 5 herein. Each of the embodiments shown have two extending latching arms 30 (one on each side of the connector 31 ) with catch mechanisms (latch pawls) 32 facing each other for connecting a second electrical connector (not shown) to the illustrated electrical connecting member 31 . The electrical cable connector member 31 of the first embodiment shown in FIG. 6 includes a terminal block 25 or housing covered by a resilient insulative material 26 to allow a user to squeeze the connector and deflect the latch arms 30 . The housing has contacts (not shown) to engage contacts of the mating connector. The latching arms 30 illustrated in FIG. 7 are not an integral part of the electrical conneting members and could be formed of a plastic material or could be formed of separate stamped pieces of metal.
[0031] [0031]FIGS. 8, 9 and 10 is illustrates the second embodiment of an electrical connecting member 31 including a terminal block 25 . Electrical conducting member 31 is matable to a complementary connector member (not shown) at a mating face in a contiguous manner. The connected members are adapted to be held together by a latch assembly in accordance with the features of the present invention to secure the two connectors together in their mated and contiguous condition. Connecting member 31 includes conducting wires 28 (FIG. 8) terminated to contacts 29 (FIG. 9). Molded integrally with terminal block 25 are latching arms 30 which each include button members 33 positioned on the lower portion 34 of the latching arms (i.e. the portion of the latching arm below the fulcrum—see FIGS. 11 and 12). Each latching arm 30 includes a distal portion carrying a catch mechanism (latch pawl) 32 disposed on each latching arm 30 . The functioning of the latch assembly is shown in detail in FIGS. 1 - 4 . Assuming that the electrical connector member 31 illustrated in FIGS. 8, 9 and 10 is in a latched state connected with its mating receptacle connector. In order to separate the electrical connector members the user first presses downwardly on push buttons 33 . Downward movement of the push buttons 33 (see FIG. 4) which are positioned on the portion of each latching arm 30 below its fulcrum member (not shown), causes outward movement of the top portions 35 of each latching arm. Each latch arm 30 resiles about its fulcrum 42 (See FIGS. 11 and 12) thereby withdrawing the catch mechanisms (latch pawls) 32 from a location behind the mating electrical connector members. This allows a user to unmate the two electrical connector members by pulling them apart.
[0032] [0032]FIGS. 11 and 12 illustrate in a clearer fashion the two embodiments of mating electrical connector members as shown in FIGS. 6 and 7, and FIGS. 8 - 10 , respectively. In FIG. 11 there is illustrated electrical conductor members 40 and 41 secured in contiguous mating relation as in FIG. 3 by catch mechanisms (latch pawls) 42 positioned on each latching arm 43 in the portion thereof above the fulcrum members 44 . Positioned below each fulcrum are push button members 45 which are pushed in the direction as illustrated in FIG. 4 so as to release the two electrical conductor members from being in mating contact with each other. FIG. 11 illustrates the embodiment in accordance with the present invention where the first electrical conducting member 40 , the push buttons 45 , the fulcrum members 44 and the catch mechanisms (latch pawls) 42 are one unitary structure, e.g. preferably formed of molded plastic. In FIG. 12 there is illustrated latching arms 43 that are formed of a separate structure from the electrical conducting member 41 (e.g. such as from stamped metal) and the fulcrum members 44 extend from the electrical conducting member 41 . Fulcrum member 44 may or may not be positioned directly against latch arm 43 . As in the structure illustrated in FIG. 11, to release electrical conducting member 41 from being in contact with another member (not shown), a force with a users fingers is applied to each latching arm 43 in the direction of arrows 50 , i.e. in the portion of each latching arm below the fulcrum members 44 (see FIG. 4).
[0033] It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims. | A latch assembly for coupling first and second connectors, which are adapted to be held in contiguous relation to one another, the assembly including at least one latching arm having upper and lower portions, the arm extending from the second connector towards the first member and having a catch mechanism on the upper portion adapted to engage the first connector and to retain the first connector to the second connector. Also included is a fulcrum mechanism adapted to allow the latching arm to pivot thereon in a manner whereby when a sufficient force is applied to the lower portion of each latching arm below the fulcrum, the upper portion of the arm deflects in an outward direction to allow unmating of the first and second connectors. | 7 |
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/438,526 filed Jan. 8, 2003 and is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to line connected devices, and more particularly to methods for transferring data to update features in a line connected device.
[0004] 2. Background of the Invention
[0005] Modern cordless telephones are evolving to include many features in addition to standard functionality for placing telephone calls. For instance, cordless telephones are now becoming available that enable users to adjust ring tone and graphics displays, and otherwise personalize the interface of the telephone. Users can make selections from lists of options stored in telephone memory to customize the telephone to each respective user's preferences.
[0006] Since cordless telephones have a limited memory capacity, only a finite number of selections are usually made available to a user for customization. In any event, no matter how many different possible options are available for selection from the memory of a telephone, users may be interested in choosing from still more options of different tunes, designs, etc. Since many consumers may be willing to purchase different selections if they were made available, a market is created for software upgrades for cordless telephones. By producing electronic devices that are upgradeable, companies can foster consumer goodwill and loyalty while still maintaining or improving profit margins.
[0007] Unfortunately, once a digital device such as a cordless telephone is released into the consumer market, it becomes very difficult to upgrade or update the telephone with new software or firmware. One obvious method for upgrading a telephone is to manually disassemble the telephone and replace the processor or memory, or temporarily remove the memory from the telephone to add new software. Of course, this method is not practical for the vast majority of consumers, who are unlikely to have the skills necessary to perform such tasks.
[0008] Even if a portable electronic device can be especially designed to enable software updates, this might not be cost effective if the benefits from including this functionality are outweighed by the associated additional costs of design and manufacture. Adding functionality to an electronic device involves additional computer architecture design, software programming, parts and components, which may be incrementally expensive. Further, regardless of the development costs, consumers will not utilize such a feature unless the steps that are necessary to update the device are relatively uncomplicated and easy to be performed. Since many portable electronic devices, such as cellular or cordless telephones, have somewhat small GUI displays with limited interfaces, this can be particularly challenging. Finally, the additional components that are necessary to enable the device to be upgraded must not overwhelm the existing physical size of the device or the spacing of other components within the device. Since, for example, cellular and cordless telephones are designed to be lightweight and comfortably hand-held, the weight and size associated with every component is always an important design consideration.
[0009] Accordingly, there is a need for a method and system for transferring data to a cordless telephone to facilitate updating and upgrading the functionality of the device, and which is relatively easy to use and does not significantly contribute to the cost, size and weight of the device.
SUMMARY OF THE INVENTION
[0010] Systems and methods are described for providing connectivity to line connected devices, such as a cordless telephone, for the purpose of upgrading software features. In a preferred embodiment, portable electronic devices can receive incoming data at the PSTN jack from a personal computer that is also connected to the PSTN via a PSTN modem. In this manner, upgrades can be accomplished without requiring users to disconnect the device or to connect additional cables or components. The telephone may be temporarily disabled from service during the downloading of the upgrade software from the personal computer to the telephone. Upgrade software can be received at the personal computer from downloads or from other sources.
[0011] The line connected device can be communicatively connected to the computer modem in several different arrangements. In one embodiment, the device and computer modem are each connected to the PSTN line along with other telephone extensions within a home, such that all devices are in parallel. The modem and device can be configured to enable an on-hook or off-hook upgrading process.
[0012] In a second embodiment, the computer modem is connected to the PSTN through an additional pass-through line jack in the line connected device, such that the two devices are serially connected. The line connected device can isolate this connection from the rest of the PSTN to facilitate direct information transfer.
[0013] In a third embodiment, the line connected device is connected to the PSTN through an additional pass-through line jack in the computer modem, so that the two devices are serially connected in a different manner. In this embodiment, the modem can isolate the connection to the PSTN for directing information transfer.
[0014] In each of these embodiments, the line connected device may be any type of device that connects to a telephone line and is capable of being upgraded in programmable memory. This may include a cordless telephone system, a corded telephone, a facsimile machine, photocopier, answering machine, etc.
[0015] A method is disclosed for programming a line connected device. Encoded signals are received at a line interface of the device. The encoded signals that include device programming signals detected and routed to programmable memory in the device. The device programming signals are transmitted to the line interface during a programming mode, telephone signals or other encoded signals are transmitted to the line interface during an operation mode, and the device switches between programming and operation modes.
[0016] A method is also disclosed for programming information in a cordless telephone. FSK encoded signals received at a line jack are decoded in a decoder. The cordless telephone detects whether the FSK encoded signals include telephone programming signals, and if so, the programming signals are routed to programmable memory in the cordless telephone.
[0017] A programmable line connected device is also described, comprising a line interface for receiving encoded signals, a detector for detecting that the encoded signals include device programming signals, and a controller for routing programming signals to a programmable memory. Device programming signals are transmitted to the line interface during a programming mode, telephone signals or other encoded signals are transmitted to the line interface during an operation mode, and the device switches between programming and operation modes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a schematic diagram of a conventional arrangement of a plurality of peripheral devices to a personal computer.
[0019] [0019]FIG. 2 is a schematic diagram of a connection of a personal computer to a base of a cordless telephone via a computer modem according to an embodiment of the present invention.
[0020] [0020]FIG. 3 is a schematic diagram of components within a base unit and a handset of a cordless telephone.
[0021] [0021]FIG. 4 is a schematic diagram of a parallel connection of a personal computer, a cordless telephone, and other telephones to a PSTN line within a home according to an embodiment of the present invention.
[0022] [0022]FIG. 5 is a schematic diagram of a computer modem connected to the PSTN through a pass-through line jack in a telephone, such that the two devices are serially connected according to an embodiment of the present invention.
[0023] [0023]FIG. 6 is a schematic diagram of a telephone connected to the PSTN through a pass-through line jack in a computer modem, such that the two devices are serially connected according to an embodiment of the present invention.
[0024] [0024]FIG. 7 is a flow diagram illustrating a method for programming a line connected device according to an embodiment of the present invention.
[0025] [0025]FIG. 8 is a flow diagram illustrating a method for programming a line connected device according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Data may be transmitted to electronic devices in several possible formats in accordance with a variety of different mechanisms. For instance, one method for communicating data to electronic devices or systems is via conventional peripheral ports on a personal computer or laptop computer, as shown in FIG. 1. As examples, a conventional printer 11 can be connected to a computer 10 via a serial/parallel connection 12 (utilizing an RS-232 cable), or a digital camera 13 may connect to a computer 10 via a USB port 14 (utilizing a USB cable). Instead of utilizing a conventional connection, it is also possible to connect a peripheral via a device-specific connection at a port 16 utilizing a device-specific protocol.
[0027] In addition to communicating data to or from such peripheral devices in the ordinary course of operation (e.g., sending information to be printed to printer 11 , or sending pictures to be stored in memory from camera 13 ), it is possible to upgrade memory within the peripherals through these connections. As an embodiment of the present invention, FIG. 2 illustrates a connection of a cordless telephone to a personal computer or laptop computer to upgrade functionality of the telephone. As can be seen, the personal computer is directly connected to the base set of the cordless telephone via a telephone line and a computer modem within the personal computer.
[0028] It is particularly advantageous to upgrade a cordless telephone via the telephone line because the cordless telephone already includes a telephone input/output jack for its normal operation. Accordingly, it is not necessary to include an additional interface component solely for the purpose of enabling upgrades. Use of other such data interfaces, such as the serial/parallel connection or USB port of a personal computer, would require different hardware that contributes to the cost of the telephone.
[0029] There are several possible protocols by which a telephone controller can enable memory in the telephone to receive software updates. For example, an option may be presented in the graphical user interface (GUI) of the telephone for the user to temporarily operate the telephone in a “programming mode.” This mode temporarily shuts down operation of the telephone so that the memory and associated processing will be allocated to receive upgrade information. As an alternative, the CPU may automatically switch the telephone into a programming mode once a signal is presented at the input port. Presence of a signal at the input port can then trigger a display at the GUI to notify the user of the status an upgrade in progress and when the upgrade is completed. However, if the upgrade will occur within only a few seconds and while the telephone is still on-hook, it may not be necessary to disable the telephone and provide status information at the GUI.
[0030] For performing upgrades according to at least one embodiment of the present invention, it is possible to use the existing processing capabilities already provided in a telephone. Particularly, modern cordless telephones and mobile cellular telephones typically include a digital signal processor (DSP) for decoding and processing control signals that are incident to the telephone from the PSTN through the advanced intelligent network (AIN). Modern telephones that are “caller-ID enabled” can decode a frequency-shift-key (FSK) encoded signal that is transmitted along with a ringing signal over the telephone network. The FSK encoded signal typically contains one or more packet headers that identifies the type of incoming data, and a payload perhaps containing a calling party name and telephone number. When this is decoded using an integrated DSP, the telephone forwards at least some of this information to the telephone display, and may also store at least the incoming telephone number in memory apportioned as a calling log. Therefore, a modern telephone already includes the necessary components and processing capability for receiving encoded signals and forwarding data to the telephone display and memory registers.
[0031] Returning to FIG. 2, it can be seen that personal computer 20 includes a computer modem 21 , which can connect to a telephone line 23 via an output jack 22 . The telephone line 23 is incoming to cordless telephone base unit 24 via telephone line input/output jack 25 . The base unit of the cordless telephone assembly communicates with the handset 26 via an RF connection.
[0032] As described above, a modern cordless telephone that is caller-ID enabled will recognize an FSK-encoded caller ID signal incoming at line input/output jack 25 as a control signal at 1200 baud. In one embodiment for performing an upgrade function, the computer modem 21 can be configured to provide a similar FSK-encoded signal provided by personal computer 20 . The FSK-encoded signal will include packet headers that indicate, instead of a caller-ID signal, an instruction that is recognized by the FSK-decoder 27 as an upgrade signal. Decoding this signal in FSK decoder 27 instructs the base unit to store the payload information as a memory upgrade.
[0033] [0033]FIG. 3 illustrates the components within the base unit 30 a and handset 30 b of the cordless telephone system. The incoming upgrade information is received in the line in/out interface 31 , where it is routed to FSK decoder 32 . Control processor(s) 33 a t hen route the decoded upgrade data to RAM 34 a , EEPROM 35 or other memory within the base. Alternatively, the data is transcoded, modulated, and transmitted to the handset through an RF connection 36 a, 36 b, where it is decompressed, demodulated and routed to RAM 34 b, EEPROM 35 b, or other memory within the handset 30 b at the direction of control processor(s) 33 b. During the time of an upgrade, the handset bus disables microphone input 37 and other input from the handset (e.g., handset keys) as well as the speaker output 38 .
[0034] Continuing with FIG. 2, in another embodiment, instead of providing an FSK-encoded signal to the telephone base unit, the modem 21 can operate in a conventional manner. That is, the modem will dial a telephone number, which will send a signal to the cordless base unit, and a modem (or a receive-only modem) within the cordless base will “pick up” the call and engage in data transfer between the devices. Advantages of this protocol are that (i) it enables higher bit-rate data transmission between the two units for transmitting more information, and (ii) it does not require modem 21 to perform in a manner that is different from its normal operation. However, additional modem-like processing capability is required at the telephone base unit to participate in modem communications with the personal computer 20 .
[0035] [0035]FIG. 4 is a schematic diagram illustrating a connection of a personal computer 40 and computer modem 41 , a cordless telephone base 43 , and an extension telephone 45 , all to a PSTN line 42 within a home. As can be seen, each of these devices are connected in parallel. In normal operation, if any of these devices goes off-hook to connect to the PSTN (e.g., to initiate or receive a telephone call, or to initiate an on-line communication), the telephone line is “occupied” such that other extensions will not be able to initiate separate communications or receive telephone calls (other than sharing the line to participate in an existing conversation).
[0036] The cordless telephone system can be upgraded while connected in the configuration of FIG. 4 either while being on-hook or off-hook. For an on-hook connection, the other extension phone 45 will not be configured to receive the FSK-encoded signal, and so it will ignore temporary signaling that will occur in the line. Likewise, the temporary signaling will be ignored by the PSTN as the signal propagates out of the home.
[0037] As was described above, the upgrade can occur while the units are on-hook by sending an FSK-encoded signal from the modem. The signal is decoded in an FSK decoder in the controller of the base unit. The decoded signal is a stream of packets, and the header indicates the address for delivery of the payload. The payload contains the software for updating ring tones, graphics displays, etc.
[0038] As an alternative embodiment, the upgrade can also occur by temporarily placing the cordless telephone off-hook. In this manner, any extension telephones 45 will not be able to utilize the network during the upgrade operation. While the line is off-hook, a standard caller-ID transfer can be initiated by the modem 41 , by sending a 1200 baud FSK signal in compliance with CID protocol. Once the information transfer is complete, the computer can then put the line back on-hook. The transmitted FSK signals will not be interpreted as a dialing command because they are comprised of a different tone set.
[0039] One problem that is associated with temporarily placing a cordless telephone off-hook is that a dial tone propagates through the line, which may interfere with the modem signals and FSK signals. One method to correct this is to use digital or analog filtering, built into the base unit, to filter out the tone. Another method is to adjust the amplitude or volume level of the modem tone to overpower the dial tone.
[0040] There are also methods to avoid the dial tone altogether. In one manner, a single DTMF digit is dialed, as if a call is being initiated. This will cause the line to become silent temporarily. During the temporary period, normal modem transfer of the FSK signal can be accomplished. As yet another method, a code can be transmitted from the telephone to the central office to request that the dial tone is temporarily disconnected.
[0041] [0041]FIG. 5 illustrates a different connection between the computer 50 and modem 51 , cordless phone base unit 52 , and PSTN line 55 as compared with FIG. 4. In FIG. 5, the cordless base unit 55 is connected to the PSTN 55 as in a conventional arrangement, but modem 51 is indirectly connected, as a “daisy chain,” to the PSTN through line 54 connected between the modem and the base unit. The base unit includes two input/output jacks, one of which is a pass-through to connect the modem. The extension phone 56 is connected to PSTN in parallel with the cordless phone. The arrangement presented in FIG. 5 can be particularly useful if a consumer wishes to connect two devices to the PSTN but has only a single telephone outlet at a particular location.
[0042] In this arrangement, the computer 50 communicates directly to the cordless telephone, which can detect when the computer modem requests to provide a download. The cordless telephone can detect this because the auxiliary input jack (connected with line 54 ) would not otherwise receive FSK-encoded signals. In response, the cordless telephone base can then isolate this connection from the rest of the PSTN so that direct information transfer can take place. Alternatively, when the telephone is in an “regular operation” mode, the modem interface jack on the cordless telephone is a mere “pass through.” However, when the telephone is switched to be in a programming mode, the modem interface jack on the cordless telephone is disconnected from the telephone line jack. In this manner, the modem will not initiate an outgoing call, and the telephone need not be placed off-hook.
[0043] [0043]FIG. 6 is similar to FIG. 5, except that in this embodiment it is the modem 61 that connects the cordless telephone base unit 62 to the PSTN 64 . The cordless telephone base is “daisy-chained” via a dedicated line 63 . The extension phone 65 is connected to the PSTN 64 in parallel with computer 60 and modem 61 .
[0044] In this arrangement, an upgrade is still initiated by computer 60 , which uses modem 61 to isolate the cordless base unit 62 from the network during the period of the upgrade. This can be done by special programming of a conventional modem, or through use of a specialized modem. From the perspective of the cordless telephone, the upgrade transaction occurs in the same manner as described with reference to FIG. 2. By including a switch in the modem that triggers between a “programmable” mode and “regular operations” mode, the modem can be configured to send signals only to the cordless telephone during programming, and not to the PSTN.
[0045] [0045]FIG. 7 is an exemplary flow diagram of a method for programming a line conmected device in accordance with one or more embodiments of the present invention.
[0046] Once an encoded signal is received at the line_in jack in the base of the cordless phone in step 71 , the signal is routed to the FSK decoder in the base controller and decoded, in step 72 . If the encoded signal includes CID information (along with a ringing signal), as determined in step 73 , the CID information is displayed on the graphical user interface in step 74 (which may be on the handset or base unit of the cordless telephone), and, depending the configuration of the cordless telephone, the CID information may be stored in a calling log, in step 75 .
[0047] If it is determined that the decoded information is not CID information, then the telephone is switched to a programming mode in step 76 , and the programming information is routed to programmable memory in step 77 . Alternatively, a user can manually switch the telephone to a programming mode before the encoded signal is received. Optionally, a step may be included to place the telephone off-hook during the update.
[0048] [0048]FIG. 8 is an exemplary flow diagram of another method for programming a line connected device in accordance with one or more embodiments of the present invention.
[0049] In this embodiment, instead of specially configuring a modem to provide FSK-encoded signals to be decoded and interpreted by the FSK decoder in the controller of the cordless telephone, the input interface can be configured to receive standard modem signals. In FIG. 8, when a user desires to program the cordless telephone, the user sets the telephone to a programmable mode, using a predetermined code sequence or a prompt on the graphical user interface, in step 81 . The user can initiates transmission of the program code through a personal computer. The cordless telephone will then receive modem initialization signals from the modem in step 82 , and will return modem initialization signals via a standard modem communications protocol to initiate a communication, in step 83 . It may be necessary to specially configure the cordless telephone to provide these initialization signals. The modem will then send payload data for receipt in the cordless telephone in step 84 , which is then routed to programmable memory in the telephone in step 85 . The payload data may be FSK encoded and decoded in the FSK decoder as described with reference to FIG. 7.
[0050] The examples described above illustrate how a line connected device can be upgraded using FSK encoded data and an FSK decoder. No particular modulation scheme is required, although it is advantageous to modulate the signal in accordance with the typical operation of the electronic device. The present invention is not intended to be limited to performing upgrades in a cordless telephone, instead, this method and system can be implemented in any telephone line connected electronic device having a DSP, and analog input and programmable storage. Examples of other such devices include corded telephones, facsimile machines, answering machines, and other computer modems.
[0051] The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
[0052] Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention. | Systems and methods are described for providing connectivity to portable electronic devices, such as a cordless telephone, for the purpose of upgrading software features. In a preferred embodiment, portable electronic devices can receive incoming data at the PSTN jack from a personal computer that is also connected to the PSTN via a PSTN modem. In this manner, upgrades can be accomplished without requiring users to disconnect the telephone or to connect additional cables or components. The telephone is temporarily disabled from service only during the downloading of the upgrade software from the personal computer to the telephone. Upgrade software can be received at the personal computer from downloads or from other sources. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/561,331 filed Dec. 16, 2003, which is a 371 of PCT/GB04/02544 filed Jun. 14, 2004, which claims priority of United Kingdom Patent Applications 031321.7 filed Jun. 12, 2004 and 329920.3 filed Dec. 24, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates to vibratory screening apparatus suitable for use with drilling fluids, mineral processing, classification, and dewatering, and the like.
BACKGROUND OF THE INVENTION
[0003] Vibratory screening apparatus is widely used in the oil drilling industry for removing drill cuttings from drilling fluids, and over the years various improvements have been made to the screens used therein, methods for mounting the screens etc to improve ease of use, reduce maintenance etc. A particular problem in offshore platform oil drilling is, however, that platform real estate is very restricted and extremely expensive. There is accordingly a need to improve the efficiency of vibratory screening apparatus in relation to the physical size thereof.
SUMMARY OF THE INVENTION
[0004] The present invention provides a vibratory screening apparatus for use in removing solids from a liquid and solids mixture feed, said apparatus comprising a static outer housing, at least one floating basket mounted so as to be vibratable, in use of the apparatus, by a vibrator device formed and arranged for vibrating said basket, said basket mounting a stack of screen assemblies, with superposed screen assemblies separated from each other by a respective flow directing tray, said apparatus being provided with a flow distributor formed and arranged for dividing said feed into at least a first feed stream and a second feed stream and directing said feed streams onto respective ones of first and second screen assemblies, and receiving filtrate from a respective screen assembly, from said respective flow directing tray(s).
[0005] With an apparatus of the present invention, the size of apparatus required to process a given volume of feed is substantially reduced compared with conventional apparatus, since a substantially increased effective screen surface area can be accommodated with relatively little or no increase in the size of the apparatus by means of stacking a plurality of screen assemblies within a single basket and using a flow distributor to route multiple flows in parallel through different screens in the stack.
[0006] Advantageously the distributor is formed and arranged so as to be switchable between a plurality of different flow directing configurations. Conveniently said plurality of flow directing configurations includes an intensive screening configuration in which the whole of the feed is directed onto said first screen assembly and the whole of the filtrate from said first screen assembly is directed onto said second screen assembly. Alternatively or additionally there is provided a restricted feed capacity configuration in which the whole of the feed is directed onto only one of said first and second screen assemblies, and the filtrate therefrom exhausted directly from the apparatus without passing through the other one said first and second screen assemblies. Such a configuration is useful for basic fluid processing where high efficiency or high volume processing are not required and a reduced number of screens in operation reduces operating cost for screens consumed.
[0007] Advantageously the mesh sizes of the various screens are selected to suit the particular distributor configuration being employed and/or the loading of the mixture (% solids content), the particle size of the solids, and/or the particle size distribution of the solids. Thus for example in a configuration where the feed is divided into one portion passing through the first screen and not the second, and another portion passing through the second screen and not the first, the first and second screens would normally have the same mesh size. On the other hand in a configuration where the whole of the feed is passed successively through both the first and second screens, then the second screen would normally have a finer mesh size than the first screen.
[0008] In general the distributor will comprise a plurality of passages provided with valves, typically flap valves, sleeve valves or plug valves, or closure plates etc, for selective opening or closing of different passages. The distributor may be mounted in either the static housing or on the floating basket. It is also possible, in principle, for part of the distributor to be mounted in the static housing and part on the floating basket. Where a greater or lesser part of the distributor is mounted in the static housing, then the distributor is generally provided with flexible conduit portions defining at least part of the passages, for coupling the passages from the static housing to the floating basket.
[0009] The passages of the distributor may be defined in various different ways. Conveniently they are defined by walls extending downwardly inside a downwardly extending chamber so as to provide a lateral subdivision of the chamber into individual passages providing predetermined proportions of the distributor flow capacity. Thus, for example, the distributor may be formed and arranged with one or more first flow passages for transmitting said first feed stream, and one or more second flow passages for transmitting said second feed stream.
[0010] It is generally preferred that vibratory screen apparatus should have a plurality of screen assembly stages with decreasing mesh size, i.e. meshes of successively finer cut. It will accordingly be appreciated that in addition to having first and second screen assemblies, with similar mesh size, formed and arranged for intercepting said first and second feed streams respectively, the vibratory basket may also have one or more further screen assemblies with different mesh size upstream and/or downstream of said first and second screen assemblies, Conveniently there is provided upstream of first and second screen assemblies, an initial, coarser mesh size, screen assembly and the vibratory screening apparatus is formed and arranged so that substantially the whole of the liquid and solids mixture feed is directed through said initial screen assembly, before being divided into said at least first and second feed streams. In such cases there would generally be used an initial screen assembly with a mesh size of around 10 to 80 (wires per inch), for example, about 20, and the first and second screen assemblies would have a mesh size of around 40 to 325, conveniently 100 to 250 for example about 200. In yet another possible distributor configuration which could also be provided, the feed is passed only through the initial coarse screen.
[0011] It will also be appreciated that, whilst in accordance with normal practice, all of the separated out solids are disposed of in one way or another, in certain cases it is advantageous to retain within the recycled drilling mud fluid, some solids within a particular size range. Typically these may comprise one or more of sized salt, sized calcium carbonate, and other suitable solids, which are selected to be of a size compatible with minimising formation damage during drilling of a specific formation such as an oil reservoir or a zone where fluid can be lost to the formation. In this instance solids above a specified size can be removed with a top screen and rejected, while solids of a smaller size but greater than a second size, can be separated with the second screen and subsequently returned to the drilling fluid mud system, with solids smaller than those removed by the second screen but larger than a third size, may be removed with a third screen and rejected. In other cases it may be desirable to return only the largest size particle fraction separated out at the first screen, for return to the drilling fluid where this is used in formations with particularly large pore size.
[0012] Various screen assemblies and screen mounting systems may be used in the apparatus and baskets of the present invention, including, for example, those described in our earlier patent publication WO 03/013690.
[0013] The floating basket may be mounted in any convenient manner known in the art. Typically there is used a resilient mounting such as a coil spring or rubber block mounting, and the basket vibrated with an eccentrically rotating weight drive. Other forms of resilient mounting may be more convenient with other forms of drive, for example, a leaf spring mounting, with the basket being vibrated with an electromagnetic displacement drive being used to displace the basket against the return force of the spring mounting
[0014] In a further aspect the present invention provides a basket suitable for use in a vibratory screening apparatus, said basket mounting a stack of screen assemblies, with superposed screen assemblies separated from each other by a respective flow directing tray, and being provided with a flow distributor formed and arranged for dividing said feed into at least a first feed stream and a second feed stream and directing said feed streams onto respective ones of first and second screen assemblies, and receiving filtrate from a respective screen assembly, from said respective flow directing tray(s).
[0015] In another aspect the present invention provides a vibratory screening apparatus for use in removing solids from a liquid and solids mixture feed, said apparatus comprising a static outer housing, at least one floating basket mounted so as to be vibratable, in use of the apparatus, by a vibrator device formed and arranged for vibrating said basket, said basket mounting a stack of screen assemblies separated by flow directing trays, said apparatus being provided with a flow distributor formed and arranged for dividing said feed into at least a first feed stream and a second feed stream and directing said feed streams onto respective ones of first and second screen assemblies, and receiving from respective flow directing trays, respective filtrates from said respective screen assemblies.
[0016] In a yet further aspect the present invention provides a basket suitable for use in a vibratory screening apparatus, said basket mounting a stack of screen assemblies separated by flow directing trays, and being provided with a flow distributor formed and arranged for dividing said feed into at least a first feed stream and a second feed stream and directing said feed streams onto respective ones of first and second screen assemblies, and receiving from respective flow directing trays, respective filtrates from said respective screen assemblies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Further preferred features and advantages of the invention will appear from the following detailed description given by way of example of preferred embodiments illustrated with reference to the accompanying drawings in which:
[0018] FIG. 1 is a schematic sectional elevation of a vibratory screening apparatus of the present invention;
[0019] FIGS. 2A to 4B are schematic vertical sections illustrating different flow paths through the stacked screens with different configurations of the flow distributor set up for parallel and series operation;
[0020] FIGS. 5A-C are schematic perspective end views of the basket of the apparatus also illustrating the flow paths in various different configurations of the flow distributor;
[0021] FIG. 6 is a side elevation of a modified apparatus with a static flow distributor connected to a floating vibratory apparatus;
[0022] FIG. 7 is a partly cut-away schematic perspective view of a further embodiment showing one module of a twin-module apparatus set up for parallel operation;
[0023] FIGS. 8A and 8B are vertical sections of the apparatus of FIG. 7 at A and B;
[0024] FIGS. 9-10 are corresponding views of the apparatus of FIGS. 7-8 , set up for series operation;
[0025] FIGS. 11-12 are schematic general side elevations of vibratory screen apparatus of the invention showing the housing; and
[0026] FIG. 13 is a schematic perspective view of the apparatus of FIG. 12 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] FIG. 1 shows schematically one embodiment of a vibratory screen apparatus 1 of the invention with an outer housing (indicated schematically) 2 , in which is mounted on springs 3 , a basket 4 . (See below for more detailed description of housing.) The basket is generally box shaped with pairs of circumferentially extending inwardly projecting flanges 5 height on the basket side walls 6 , for supporting respective ones of a stack 7 of screen assemblies 8 separated by flow directing trays 9 . A vibrator unit 10 is secured to the top 11 of the basket. (Alternatively, the vibrator 10 could be mounted on a side of the basket 4 , or incorporated into or within the structure of the basket 4 . The interior 12 of the basket 4 is divided into a series of levels 13 between neighbouring screen assemblies 8 and flow directing trays 9 .
[0028] FIGS. 2 A/B to 4 A/B show schematically a distributor 15 provided at one end 16 of the floating basket 4 . The distributor 15 is formed and arranged into inside and outside passages 17 , 18 shown in FIGS. 2A to 4A , and 2 B to 4 B, respectively, for connecting with the various levels 13 of the interior 12 of the basket 4 via openings 19 controlled by flap valves 20 . In some cases the flap valves 20 are additionally used to control openings 21 along the length of the passages 17 , 18 in certain positions of said flap valves 20 , as further described hereinbelow.
[0029] FIGS. 2 A/B, 3 A/B and 4 A/B show different configurations of the distributor 15 for providing different feed flow arrangements through the screen assemblies 8 , which are indicated as A, B and C, respectively, in FIGS. 2 to 5 .
[0030] In more detail FIG. 2A shows the inside passage 17 and interior 12 of the basket 14 , with an upper flap valve 20 ′ raised to open an upper connecting opening 19 ′ connecting the passage 17 and first level 13 1 above the upper flow deflector tray 9 ′. An intermediate flap valve 20 ″ is raised to close an intermediate connecting opening 19 ″ connecting the passage 17 and second level 13 2 between the upper and lower flow deflector trays 9 ′, 9 ″ whilst simultaneously opening an intermediate level opening 21 ′ in passage 17 . A lower flap valve 20 ′″ is lowered to open a lower connecting opening 19 ′″ connecting the passage 17 and a fourth level 134 below the lower flow deflector tray 9 ″. In this configuration it may be seen that a feed 22 of liquid and solids is passed through a coarse mesh, (typically mesh size 20) upper screen 8 ′ and the filtrate 23 passed along the upper flow deflector tray 9 ′ into passage 17 and thence, bypassing a first, mid-level, screen 8 ″, onto a second, low-level, screen 8 ′″. In this configuration the whole of the feed 22 is passed through the coarse screen 8 ′ and only one of the first and second screens 8 ″, 8 ′″.
[0031] FIG. 3B shows the distributor 15 configured so that the upper flap valve 20 ′ is raised to open the upper connecting opening 19 ′, the intermediate flap valve 20 ″ is lowered to open the intermediate connecting opening 19 ″ whilst simultaneously closing the intermediate level passage opening 21 ′, and the lower flap 20 ′″ is lowered to open the lower connecting opening 19 ′″ whilst closing a bottom passage opening 21 ″ as before. In this configuration the whole of the feed 22 is passed through the coarse screen 8 ′ and then successively through each of the first and second screens 8 ″, 8 ′″ thereby providing a more progressively finer screening of the feed (by using a finer mesh size in the second screen than in the first screen).
[0032] FIG. 4A shows the distributor in the inside passage 17 configured so that the upper flap valve 20 ′ is raised as before. The intermediate flap valve 20 ″ is lowered so as to open the intermediate connecting opening 19 ″ whilst simultaneously closing the intermediate level passage opening 21 ′ and the lower flap 20 ′″ is raised to close the lower connecting opening 19 ′″ whilst opening the bottom passage opening 21 ′″. In this configuration of the inside passage 17 in the distributor 15 , that part 23 ′ of the filtrate 23 from the coarse screen 8 ′ passing into the inside passage 17 , is directed onto the first screen 8 ″ and then out of the bottom opening 21 ″ of the inside passage 17 , by-passing the second screen 8 ′″. The outside passage 18 is configured as in FIG. 2A so that the remaining part 23 ″ of the filtrate 23 from the coarse screen 8 ′ passing into the outside passage 18 , is directed onto the second screen 8 ′″ by-passing the first screen S″. It will be appreciated that in this configuration of the distributor 15 , the screen area available for screening of the feed 22 is effectively double that used in FIG. 2 A/B and that available in a conventional vibratory screening apparatus basket of similar footprint.
[0033] FIGS. 5A-C are schematic perspective views of the end 16 of the basket 4 to which the distributor 15 is coupled but with the distributor 15 substantially removed for clarity, showing the flows in and out of the various openings 19 connecting the distributor 15 to the interior 12 of the basket 4 .
[0034] FIG. 6 shows schematically another embodiment in which there is used a distributor 24 mounted on the static housing 2 and with its connecting openings 19 coupled to the corresponding levels 25 inside the floating basket 4 by flexible conduits 26 .
[0035] FIG. 7 shows a further embodiment of a screening apparatus 27 of the invention which has identical twin modules 28 , 29 (only one shown in detail). Each module has a first, coarse mesh, upper, scalping, deck 30 with a first, coarse mesh, screen 31 above a flow back tray 32 . Fluid 33 to be screened is retained on the screen 31 by an end wall 34 .
[0036] Below the first deck tray 32 is disposed a second deck 35 comprising a second screen 36 above a respective flowback tray 37 . A certain amount of fluid 38 is retained on the second screen 36 by a weir 39 provided at the lower end 40 thereof. When the flow rate of the feed of fluid 33 to be screened, exceeds the capacity of the second screen, part 41 of the fluid 38 overflows the weir 39 either directly into one or other of two vertically extending conduits 42 at opposite sides of the module 28 , or onto one or other of two sloping deflector plates 43 which divert it into a respective one of the conduit 42 , as shown by the single headed fluid flow arrows in FIGS. 7-8 .
[0037] At the bottom 44 of the vertical conduits 42 are provided rearwardly facing openings 45 through which the diverted fluid 41 is directed onto the screen 46 of a third deck 47 disposed below the second deck 35 . Thus this part 41 of the fluid flow 33 passes through the first deck screen 31 and the third deck screen 46 , by-passing the second deck screen 36 (see also FIGS. 8A and 8B , in which FIG. 8A is a section through a central vertical plane at A, which extends through a central portion 48 of the module 28 , with the deflector plates 43 ; and FIG. 8B is a vertical section through one of the vertically extending side conduits 42 ).
[0038] That part 38 of the fluid 33 retained on the second screen 36 is passed through the second deck screen 36 (the solid particulate material 49 retained thereon being “walked up” the screen 36 in the usual way—see FIG. 8B ), as indicated by the double headed arrows 50 . This part 50 of the fluid flow 33 , is then passed through a second deck end wall opening 51 and down a central vertically extending conduit 52 underneath the deflector plates 43 . A closure panel 53 seals a third deck end wall opening 54 , below the second deck end wall opening 51 , thereby preventing this part 50 of the fluid flow 33 from entering the third deck 47 . A bottom opening 55 in the central vertical conduit 52 allows this fluid flow 50 to pass into the sump 56 of the apparatus 28 where it rejoins the other part 38 of the fluid flow 33 , the respective parts 41 and 38 , 50 of the fluid flow 33 , being passed through the first deck screen 31 and then, in parallel, through a respective one of the second and third deck screens 36 , 46 .
[0039] The module 28 as described above, may be readily reconfigured for serial operation whereby the whole of the fluid is passes through each one of the first, second and third deck screens, 31 , 36 , 46 , as shown in FIGS. 9-10 . In more detail the weir 39 is replaced by a high wall 57 which ensures that the whole of the fluid flow 33 is passed through the second deck screen 36 . As before, the fluid flow 58 then passes out through the second deck end wall opening 51 into the central vertical conduit 52 . In this configuration, the bottom opening 55 is sealed by a closure plate 59 whilst the closure panel 53 of the third deck end wall opening 54 is opened so that the fluid flow 58 is routed from the central vertical conduit 52 into the third deck 47 and passed through the screen 46 thereof into the sump 56 .
[0040] Each of the first and second modules 28 , 29 , would normally be configured in the same way, but if desired they could be configured differently i.e. one for parallel (2 screen) operation and one for series (3 screen) operation. Also single screen operation is possible when required, by removing one or two screens from the or each module—depending on the configuration of the modules and the fluid feed arrangement. In addition the fluid feed to the apparatus can be arranged to be directed to either or both of the modules (see also further discussion hereinbelow with reference to FIG. 13 ). With the significantly increased fluid processing capacity of the apparatus (in parallel mode) it will be appreciated that occasions will arise when the fluid feed is insufficient to maintain a high fluid level and short beach length on the screens, which can result in drying of the particulate solids on the beach portion of the screen and damage to the screens therefrom, and/or reduced efficiency of transportation of the particulate solids up the beach for discharge from the screen. In such circumstances damage to the screens can be minimized by restricting the fluid feed to only one of the twin modules.
[0041] A particular advantage of this type of embodiment is that, in its parallel configuration, a more even and controlled distribution of the fluid flow across the width of the module is obtained, thereby providing a more efficient screening. Another significant advantage is a significantly increased fluid screening capacity—which can approach almost 100% greater than with conventional screening apparatus of the same footprint.
[0042] It will also be appreciated that various parameters of the modules may be made further configurable. Thus, for example, the weir height could be configurable for a series of different heights. Also the relative proportions of the central and side, vertical conduits could be selected to accommodate particular desired flow capacity proportions for the different fluid flow parts in parallel mode operation.
[0043] It will further be appreciated that various modifications may be made to the above embodiments without departing from the scope of the present invention. Thus, for example, in place of a flow distributor system based on the use of closure plates and/or flap valves, there could be used one based on proportional valves and the like.
[0044] FIGS. 11 to 13 show a vibratory screening apparatus 1 of the invention with a generally conventional form of static outer housing 2 , in which is mounted on springs 3 , and a basket 4 with a vibrator device 10 . In more detail the static housing 2 has a base support 60 which includes a sump 61 for receiving filtrate 62 from the basket 4 , and a feed device support portion 63 mounting a feed device 64 . The feed device 64 comprises a header tank 65 for receiving a liquid and solids mixture feed 66 , and having a feed chute 67 extending out therefrom above the basket 4 so as to pass said feed 66 into the basket 4 . In the case of FIG. 11 , there is provided a static flow distributor 24 mounted on the header tank portion 65 of the static housing 2 , and coupled to the floating basket 4 via flexible conduits 26 . In the case of FIGS. 12 and 13 , the flow distributor 15 is incorporated in the floating basket 4 .
[0045] In the apparatus shown in FIG. 13 it may be seen that the basket 4 has a lateral divider 68 separating the basket into two independently operable basket feed processing modules 69 , 70 , and the (common) housing 2 has two separate feed chutes 71 , 72 extending from the header tank 65 and formed and arranged for directing said liquid and solids mixture feed 66 A, 66 B to respective ones of said basket feed processing modules 69 , 70 . The chutes 71 , 72 are provided with respective control gates 73 , 74 for controlling supply of feed 66 from the header tank 65 , so that the user has the option of using only one or other, or both, of the modules 69 , 70 , when required—as discussed hereinbefore. | The present invention provides a vibratory screening apparatus ( 1 ) for use in removing solids from a liquid feed, and a basket ( 4 ) therefore. The apparatus comprises a static outer housing ( 2 ), and a floating basket vibratable by a vibrator device ( 10 ). The basket mounts a stack ( 7 ) of screen assemblies ( 8 ) provided with respective flow directing trays ( 9 ) for receiving filtrates from the screen assemblies. A flow distributor ( 15 ) divides the feed into at least first and a second feed streams and directs them onto respective screen assemblies, and receives from the flow directing trays, filtrates from respective screen assemblies. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the scientific technology of automatic shutting pull door, and in particular, to a damped closing mechanism for automatic shutting pull door in which the automatic closing mechanism can perform a varied damping effect to alleviate the closing force and retard the travelling speed when the moving door panel is about to reach the final shut position so as to avoid the door panel to collide with the door post too forcibly that might result in damaging the door.
[0003] 2. Description of the Prior Art
[0004] For the purpose of performing closing and opening operation of the door efficiently and silently, an automatic door closing mechanism is employed. For example, in order to avoid too loud bumping noise and accidental disruption of a door when closing it too forcibly, an automatic closing mechanism is provided for a revolving or a pull door to alleviate the closing impulse or retard closing speed. As for a pull door in which the door panel makes transverse displacement, there have been disclosed many kinds of automatic closing mechanism with a variety of functions, namely, “Speed Governor for Automatically Shutting Pull Door” (Taiwan Pat. No. 445340), “Locking Device of Pull Door” (Taiwan Pat. No. 1295335), and “Automatic Closing Device for Pull Door” (Taiwan Pat. No. 200743717) etc.
[0005] Take the last one for example, it has successfully eliminated the prior flaw of employing a bulky and awkward rack rail in its automatic closing device, however, it has not been liberated form the conventional disadvantage of lacking damping effect of the helical spring in the closing device that results in failing to lower the travelling speed of the door panel, and causing a loud bumping noise or even disruption of the mechanism or door itself when the door is closed.
[0006] In view of the foregoing situation, the inventor of the present invention herein has gone to great length of intensive research based on many years of experience gained through professional engagement in the manufacturing of the related products, with continuous experimentation and improvement culminating in the development of the present invention.
SUMMARY OF THE INVENTION
[0007] Accordingly, the object of the present invention is to provide a damped closing mechanism for automatic shutting pull door having a change over device capable of changing the damping effect generated nearby the closing position of the door so as to alleviate colliding speed and impulse of the moving door panel with the door post when shutting without affecting pulling of the door panel before closing.
[0008] To achieve the afore said object, the gist of the present invention is to provide a damped closing mechanism essentially comprising a base, a screw wheel, a change over device and a brake gear.
[0009] The screw wheel is erected on the base and having a coil spring to produce a restoring resilient force. The screw wheel is able to wind back and stretch out a rope whose exposed end is fasten to a door panel or door frame where the damped closing mechanism being not installed so as to stretch out the rope when the door panel is away form the shut position; and when liberating the door panel, the screw wheel winds back the rope to move the door panel to approach the shut position.
[0010] The change over device is erected on the base and having a first and a second rocking bars radially extended with an angle therebetween. The size of opened angle depends on the predetermined retarding distance for the screw wheel to go. There is a brake member provided at the nearby door closing position on the door frame or door panel to where the exposed end of the rope is fastened for stirring up the first and the second rocking bars.
[0011] The brake gear erected on the base revolves simultaneously with the screw wheel. There is a damping element contained in the brake gear to provide a damping effect. Corresponding with the first and second rocking bars, there are a first and a second positioning dents formed on the brake gear, and a corresponding ball button is provided on the sidewall of the base for the change over device to vary the damping effect of the brake gear.
[0012] With this scheme, when the door panel approaches the door closing position, the change over device actuates the brake gear to vary its position to begin damping so as to alleviate the colliding force and speed of the door panel with the door post yet without affecting pulling back of the door panel before closing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Other objects and purposes of the invention will be apparent to persons acquainted with apparatus of this general type upon reading the following specification and inspection of the accompanying drawings.
[0014] FIG. 1 is a perspective view of the present invention.
[0015] FIG. 2 is a perspective view showing the component arts inside of the closing mechanism according to the present invention.
[0016] FIG. 3 is a rear view of FIG. 2 .
[0017] FIG. 4 through FIG. 6 are schematic views respectively showing the location of the closing mechanism when the door is closed, starting to close and approaching closed position.
[0018] FIG. 7 is a schematic view the door is shut whereas the closing mechanism is installed at other side of the door panel.
[0019] FIG. 8 is a schematic view after operation whereas the closing mechanism is installed at the other side opposite to that of FIG. 7 .
[0020] FIG. 9 through FIG. 11 are illustrative views respectively showing the component parts of the closing mechanism before, at and after operation.
[0021] FIG. 12 is a schematic view of the change over device in second embodiment of the present invention.
[0022] FIG. 13 and FIG. 14 are three-dimensional views showing respectively the state of closing mechanism before and after operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to FIG. 1 through FIG. 3 , the damped closing mechanism for automatic shutting pull door of the present invention comprises a base 10 , a screw wheel 20 , a change over device 30 , a brake gear 40 and a rope 50 .
[0024] Referring further to FIG. 4 through FIG. 6 for understanding more detailed scheme, wherein the base 10 is a shaped frame member having a fence 15 to enclose the bottom and side opening around the base 10 such that an upwardly opened accommodation space is formed between the base 10 and the fence 15 .
[0025] The screw wheel 20 is erectly housed in the accommodation space between the base 10 and the fence 15 . The screw wheel 20 contains a coil spring (not shown) capable of producing a restoring resilient force when recoiling and making the screw wheel 20 to wind back or extend the rope 50 . The screw wheel 20 is provided with an elastic limit member 24 for limiting its revolution and an adjustable mechanism 26 to adjust resilience of the coil spring. The forward rotation of the adjustable mechanism 26 coils up the coil spring and strengthen its resilient force, and vice versa. A driving gear wheel 21 is attached to the shaft of the screw wheel 20 and mated with a gear unit 22 (see FIG. 3 ). The driving gear wheel 21 , the gear unit 22 , or the driving gear wheel 21 along with the gear unit 22 can be coupled with a damper 23 , either a viscous damper or an oil-damping device to enforce the retarding effect of the screw wheel 20 thereby stabilizing the restoring force of the coil spring. As a result, accidental loosening of the rope 50 during winding back or extending out by the rotation of the screw wheel 20 can be avoided. Meanwhile, a guide-rolling wheel 25 is provided on the base 10 above the exterior of the screw wheel 20 .
[0026] Here, the change over device 30 is erectly housed in the accommodation space between the base 10 and the fence 15 and located in a position at the opposite side of the guide rolling wheel 25 of the screw wheel 20 . The change over device 30 has a first and a second rocking bars 31 and 32 extended radially outward with and angle formed therebetween (see FIG. 9 through FIG. 11 ). The size of aforesaid angle is designed according to a predetermined retarding rotational distance of the screw wheel 20 . On the inner side ends of the two rocking bars 30 , 31 there are formed arcuate protuberances 311 , and 321 respectively to perform change over operation. A driving gear 33 is engaged with the shaft of the change over device 30 (see FIG. 2 and FIG. 3 ) to actuate simultaneously at least one combined conversion gear 34 to simultaneously actuate the brake gear 40 . The driving gear 33 is directly in mesh with the brake gear 40 to drive the brake gear 40 . As show in FIG. 12 , the arcuate protuberances 311 , 321 may be configurated into a desired shape according to the actual needs.
[0027] Meanwhile, the size of a door panel 2 must allow at least one damper 35 installed around the vicinity of those component parts of the change over device 30 , e.g. the driving gear 33 , conversion gear 34 , or the paired driving gear 33 and conversion gear 34 to conjoin with so as to provide the retarding effect for the change over device 30 .
[0028] In an embodiment of the present invention, the brake gear 40 is in mesh with the conversion gear 34 , but it is not limited only as such. As shown in FIG. 3 , the brake gear 40 is equipped with a damping element 44 to serve braking and retarding effect for the screw wheel 30 to liberate the rope 50 . The brake gear 40 is able to be in mesh with at least one nearby damper 43 to provide retarding effect for itself.
[0029] The brake gear 40 has at least two positioning dents formed along its own edge at a position opposite to the screw wheel 20 . In this embodiment two dents, a first and a second dents 41 and 42 are formed, and a corresponding ball button 45 is provided on the side fence surface of the base 10 . There is a cavity 451 with a spring 452 and a rolling element 453 formed inside of the ball button 45 . At the side of the ball button 45 is an adjuster 455 to adjust the resilience of the spring 452 to provide the rolling element 453 with an adjustable pre-pressure thereby bringing the rolling element 453 to be trapped into the first or the second dents 41 , or 42 and positioned thereat.
[0030] With this scheme, a damped closing mechanism for automatic shutting pull door can be operated to retard the travelling speed of the door panel when shutting through the use of the change over device 30 .
[0031] In practical application, reference can be made to FIG. 4 though FIG. 6 , or FIG. 7 through FIG. 8 , the damped closing mechanism is bolted to the door panel 2 , or a door frame 1 with screw 3 , it is preferable to install the mechanism on the door panel 2 as near as possible to the door frame 1 . In the embodiments of the present invention the closing mechanism is essentially bolted to the door panel 2 . The exposed end of the rope 50 which being coiled in the screw wheel 20 is fastened to an appropriate position on the door frame 1 with a fixing member 51 . There is a brake member 60 attached to the door frame 1 or panel 2 near the shut position where a fixing member 51 to fix the exposed end of the rope 50 is fastened. The brake member 60 actuates the change over member 30 before shutting the door panel 2 .
[0032] By so, when the door panel 2 is pushed in the opening direction, the rope 50 will be extended by the guide rolling wheel 25 , the screw wheel 20 rotates to coil up the coil spring to store the resilient force towards the shutting direction. At the time the door panel 2 goes apart from its shut position, the brake member 60 will actuate the first rocking bar 31 of the change over device 30 on time (see FIG. 9 and FIG. 13 ) so as to drive the brake gear 40 to rotate thereby causing the ball button 45 to trap into the first dents 41 of the brake gear 40 and positioned there (see FIG. 10 ). As a result, the damping force of the brake gear 40 is varied causing the door panel 2 easy to be opened.
[0033] On the contrary, when the door panel 2 is liberated, screw wheel 20 will use its restored resilient force to wind up the rope 50 thereby urging the door panel 2 to move towards closing direction. The screw wheel 20 themselves contains a damper 23 to avoid sudden movement of the door panel 2 . The travelling speed of the door panel 2 in closing direction is greater than the winding up speed of the rope 50 by the screw wheel 20 . When the second rocking bar 32 of the change over device 30 is in touch with the brake member 60 (see FIG. 11 . Through FIG. 14 ), the brake gear 40 will be driven by the change over device 30 to counteract instantaneously the moving force of the door panel 2 by the cooperated action of the brake gear 40 and the ball button 45 , and at the same time, the rolling element 453 of the ball button 45 removes from the first dent 41 to the second dent 42 , at this moment the screw wheel 20 has already wound back the rope 50 . Then again the change over device 30 actuates the brake gear 40 and at least one damper 43 simultaneously to rotate so as to enhance the damping effect of the brake wheel 40 thereby making the door panel 2 to move under the cooperated damping effect of the screw wheel 20 and the brake gear 40 and the screw wheel 20 uses its remaining restored resilient force to wind back the rope 50 .
[0034] In the present invention, the cooperated function of the ball button 45 and the second dent 42 of the brake gear 40 further serves to alleviate the restoring resilient force of the coil spring in the screw wheel 20 and retards the moving speed of the door panel 2 towards closing direction so as to restrain bumping impulse and the noise when door is shut but without delaying the returning time of the door to the shut position too long.
[0035] It is apparent to a person skilled in the art that the basic idea of the invention can be implemented in many different ways. The invention and its embodiments are thus not restricted to the examples described above, but may vary with the scope of the following claims. | In a damped closing mechanism for automatic shutting pull door, a door closing mechanism includes a screw wheel to store restoring force, a change over device and a brake gear to produce a damping effect is integrally combined and equipped on the frame of a moving door panel. The brake gear is to alleviate the actuating force and moving speed of the door panel provided by the screw wheel. The change over device is capable of changing the damping effect of the brake gear to generate nearby the closing position of the door so as to alleviate colliding speed and impulse of the moving door panel with the door post when shutting without affecting the pulling of the door panel before closing. | 4 |
STATEMENT OF RELATED APPLICATIONS
This patent application is based on and claims priority on German Patent Application No. 10 2006 031 144.2 having a filing date of 4 Jul. 2006.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method for operation of a wind energy installation having a rotor which can be driven by wind and has at least one rotor blade, having a generator for conversion of the mechanical energy of the rotor to electrical energy, and having a tower on which the rotor is arranged. The present invention also relates to a wind energy installation which is operated using this method.
2. Prior Art
Wind energy installations are subject to particularly high loads in strong winds. Wind energy installations are generally designed such that, in the extreme, they can withstand wind speeds which correspond to those of the so-called once-a-century gust.
However, even in Europe, extreme wind conditions are occurring ever more frequently, with wind speeds which may be above the once-a-century gust. Furthermore, for example in the USA or Australia, there are wind energy installation locations at which it is possible for cyclones or the like to occur. Cyclones can cause wind-dependent forces acting on the wind energy installation which considerably exceed the loads resulting from a once-a-century gust.
Guys are known for stabilization of buildings in general against external influences, in particular wind. In this case, a plurality of cables, chains or the like which originate from the building to be stabilized are tensioned, and are anchored in the ground. However, the permanent use of guys such as these for wind energy installations would have considerable disadvantages. This is because wind energy installations are subject to dynamic loads. The forces introduced into the wind energy installation as a result of the guys—particularly as a result of the dynamic loads on the wind energy installations—would lead to fatigue problems at those points or in those areas of the wind energy installation into which the forces are introduced.
BRIEF SUMMARY OF THE INVENTION
One object of the present invention is therefore to specify a method for operation or stabilization of a wind energy installation, by means of which the wind energy installation can be stabilized as optimally as possible, while the corresponding stabilization measures result in as little load as possible on the wind energy installation, at the same time.
A further object of the invention is to specify a wind energy installation which can be operated using this method.
This object is achieved by a method for operation of a wind energy installation having a rotor which can be driven by wind and has at least one rotor blade, having a generator for conversion of the mechanical energy of the rotor to electrical energy, and having a tower on which the rotor is arranged, characterized in that, in order to guy the wind energy installation, a guy apparatus is changed as required automatically from an unstressed state—or at least less-stressed state—to a stressed state—or at least more-stressed state—which stabilizes the wind energy installation.
Accordingly, according to the invention, in order to guy the wind energy installation, a guy apparatus is changed as required automatically from an unstressed state—or at least less-stressed state—to a stressed state—or at least more-stressed state—which stabilizes the wind energy installation.
For the sake of simplicity, the following text refers exclusively to a “stressed” or an “unstressed” state. The features of the present invention which are described in the following text in conjunction with these states are intended to relate—without this being expressly mentioned—to the abovementioned change of the guy apparatus from a “less-stressed state” to a “more-stressed state”, as well.
The particular advantage of the invention is, in particular, that the wind energy installation is guyed only when necessary. The guy apparatus is activated only when stabilization of the wind energy installation is necessary, for example as a result of the current wind conditions. The guy apparatus is unstressed when not activated, so that no guy-dependent forces loading the installation are introduced into the wind energy installation. This effectively reduces fatigue on those components of the wind energy installation which are loaded by the guy. One further particular advantage of the invention is that the guy apparatus is automatically changed from the unstressed state to the stressed state.
The guy apparatus is preferably changed from the unstressed state to the stressed state as a function of current wind conditions and/or wind conditions to be expected in the future, in particular storm gusts or the like, and/or as a function of current earth movements and/or earth movements to be expected. The guy apparatus is accordingly stressed in order to stabilize the wind energy installation when the wind conditions or other external influences make this necessary. If, by way of example, prediction systems predict storms with such a high wind speed that the wind energy installation could be damaged, the guy apparatus can be stressed. A similar situation exists in the case of currently measured earth (ground) movements or earthquakes or when such events are to be expected, which could cause the wind energy installation to oscillate, so that additional guying could appear worthwhile.
In one particular embodiment of the present invention, the guy apparatus can be stressed, that is to say it is changed from the unstressed state to the stressed state, once, for example, a critical storm and/or earthquake has been predicted by a specialized institute. In this case, the institute making the prediction can send an activation signal, in particular from an appropriate signal generator, to a control device for the wind energy installation, for example an electromagnetic signal such as a radio signal, a signal which can be transmitted via the Internet, or the like. The control device can then initiate the stressing of the guy apparatus as a function of the activation signal.
In a further embodiment, it is possible to provide for the wind conditions and/or the ground movements at the location of the wind energy installation and/or in the physical vicinity of the wind energy installation to be recorded by means of suitable sensors, in particular on the side of the wind energy installation facing the wind. However, the wind conditions can also be derived from operating parameters of the wind energy installation, for example from the rotation speed of the rotor, the wind incidence angle of the rotor blade or the like. The guy apparatus can then be changed from the unstressed state to the stressed state as a function of the wind conditions and/or earth movements determined in this way.
The guy apparatus is preferably changed from the unstressed state to the stressed state when a characteristic value which characterizes the wind conditions and/or the earth movements exceeds a predetermined limit value.
The guy apparatus is preferably changed back to the unstressed state again when the wind conditions and/or the earth movements allow this. This may be done in particular after a predetermined time period has elapsed and/or as a function of current wind conditions and/or wind conditions to be expected, and/or as a function of current earth movements, and/or earth movements to be expected. When no more loads on the wind energy installation are to be expected or are currently being measured on this basis, the reverse change can be initiated in order to free the wind energy installation of the loads produced by the guying.
The object of the present invention is also achieved by a wind energy installation having a rotor which can be driven by wind and has at least one rotor blade, having a generator for conversion of the mechanical energy of the rotor to electrical energy, having a tower on which the rotor is arranged, characterized by a guy apparatus which has tensioning means, which can be tensioned controllably and can be changed as required automatically from an unstressed state—or at least from a less-stressed state—to a stressed state—or at least to a more-stressed state—which stabilizes the wind energy installation.
Accordingly, a wind energy installation which is being operated using the method as described above has a guy apparatus which has tensioning means, which can be tensioned controllably and can be changed as required automatically from an unstressed state or to a stressed state which stabilizes the wind energy installation.
The tensioning means may, for example, be cables, chains or the like which are connected at one end to the tower of the wind energy installation and/or to the nacelle. The tensioning means are preferably anchored or can be anchored, at the other end directly or indirectly in the ground. In this embodiment, the tensioning means run obliquely downward, starting from the wind energy installation, to the respective anchorage points in the ground, which are arranged around the wind energy installation.
The guy apparatus can be controlled by means of an open-loop/closed-loop control device as a function of the wind conditions and/or earth movements which are currently being recorded and/or are to be expected in the future. The tensioning means are accordingly stressed when this is necessary as a result of the wind conditions and/or the earth movements.
For automatic stressing of the tensioning means, the guy apparatus can have a motor, in particular electric-motor, hydraulic or pneumatic drive, via which the tensioning means can be stressed.
In one particularly preferred embodiment of the present invention, the rotor of the wind energy installation is braked before the guy apparatus is changed from the unstressed state to the stressed state, in particular by suitable variation of the wind incidence angle on the rotor blades and/or by operation of mechanical rotor brakes. Since the rotor blades are braked before the guy apparatus is stressed, the tensioning means of the guy apparatus can be stressed without impediment without any need to be concerned about collisions between the tensioning means and the rotor blades as a result of the rotation of the rotor blades. The tensioning means, for example the cables, can then be attached to the tower of the wind energy installation for example particularly high up, without the cables, which run obliquely downwards from the tower in the stressed state, being hit by the rotating rotor blades.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the present invention are specified in the attached dependent claims, in the following description of one preferred exemplary embodiment, and in the attached drawing, in which:
FIG. 1 shows a schematic side view of a wind energy installation according to the invention with a guy apparatus.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a wind energy installation 10 . The wind energy installation 10 has a nacelle 16 , which is arranged at the top of the tower, at the upper end of a vertical tower 14 which is arranged on a horizontal base 12 . As a person skilled in the art knows from the prior art, many embodiments are feasible for the detailed design of a tower 14 for a wind energy installation 10 . The invention is not, of course, restricted to the truncated-conical form of the tower 14 described in the drawing.
A rotor 18 is arranged at an end of the nacelle 16 facing the wind, and has a hub 20 . Three rotor blades 22 are connected to the hub 20 , with the rotor blade roots 23 of the rotor blades 22 being inserted into appropriate openings in the hub 20 , and being connected to it in a known manner.
The rotor 18 rotates about an axis which is inclined slightly upward with respect to the horizontal. As soon as wind strikes the rotor blades 22 , the rotor 18 is caused to rotate about the rotation axis, together with the rotor blades 22 . The movement of the rotor shaft is converted to electrical power by a generator which is arranged within the nacelle 16 . The rotor blades 22 cover a circular area during rotation. The positions of the rotor blades 22 with respect to the wind can be varied individually by means of an adjustment device, which is not illustrated but is known to those skilled in the art from the prior art, that is to say the incidence angle of the rotor blade 22 with respect to the wind is adjustable. Various functions of the wind energy installation 10 can be controlled by a suitable control device, which is not illustrated.
The wind energy installation 10 is connected to an electricity grid system, into which the electrical energy produced by the generator can be fed.
The basic design of the wind energy installation 10 with an at least approximately horizontal rotor axis is known from the prior art, so that this will not be described in detail.
The tower 14 of the wind energy installation 10 is guyed by means of a guy apparatus 24 , that is to say it is stabilized with respect to external influences, such as wind gusts or earth movements, in particular relatively minor earthquakes. The guy apparatus 24 has three upper tensioning means 28 as well as three lower tensioning means 26 , which each end at the tower 14 of the wind energy installation 10 . Only four tensioning means of the tensioning means 26 , 28 can in this case be seen in the present side view. All of the tensioning means 26 , 28 are in the form of cables.
The upper tensioning means 28 are connected to the tower 14 in its upper third. Starting from the attachment points 29 , they run obliquely downwards and end in the immediate vicinity of the tower 14 at anchoring devices 30 for the guy apparatus 24 .
The anchoring devices 30 are anchored in the ground 12 by means of anchoring foundations, which are not shown.
The lower tensioning means 26 are connected to the tower 14 in its lower half. Starting from attachment points 32 , they likewise run obliquely downwards to the anchoring devices 30 for the guy apparatus 24 .
The anchoring devices 30 for the guy apparatus 24 have drives, specifically electric motors, via which the tensioning means 26 , 28 can be changed by means of cable winches, which are not illustrated, from an unstressed state, which is not illustrated, to the stressed state as shown in FIG. 1 . For this purpose, the tensioning means 26 , 28 are each wound up in a manner known per se by means of the cable winches onto appropriate cable winch drums. In order to change the tensioning means 26 , 28 back to the unstressed state, the tensioning means 26 , 28 can be unwound from the cable winch drum. In the unstressed state, the tensioning means 26 , 28 , that is to say the cables, hang down loosely adjacent to the tower 14 in places, and lie on the ground 12 in places.
The guy apparatus 24 can be controlled by means of an open-loop/closed-loop control device, which is associated with the wind energy installation 10 , as a function of the currently recorded wind conditions and/or earth movements and/or similar events to be expected in the future. The tensioning means 26 , 28 are automatically stressed in a corresponding manner when this is necessary as a result of the wind conditions and/or the earth movements.
Specifically, the guy apparatus 24 is changed from the unstressed state to the stressed state as a function of an activation signal which is transmitted to the open-loop/closed-loop control device directly or indirectly from an institute predicting wind and/or earth movements.
Alternatively or additionally it is feasible for the wind conditions and/or the earth movements at the location of the wind energy installation 10 and/or in the physical vicinity of the wind energy installation 10 to be recorded by means of suitable sensors, in particular on the side of the wind energy installation 10 facing the wind. The wind conditions can also be derived from operating parameters of the wind energy installation 10 , for example from the rotation speed of the rotor 18 , from the wind incidence angle of the rotor blade 22 , or the like.
The guy apparatus 24 is changed back to the unstressed state after a predetermined time period has elapsed and/or as a function of current wind conditions and/or as a function of current earth movements.
LIST OF REFERENCE SYMBOLS
10 Wind energy installation
12 Base
14 Tower
16 Nacelle
18 Rotor
20 Hub
22 Rotor blades
23 Rotor blade root
24 Guy apparatus
26 Lower tensioning means
28 Upper tensioning means
29 Attachment points
30 Anchoring device
32 Attachment points | A method for operation of a wind energy installation having a rotor ( 18 ) which can be driven by wind and has at least one rotor blade ( 22 ), a generator for conversion of the mechanical energy of the rotor ( 18 ) to electrical energy, a tower ( 14 ) on which the rotor ( 18 ) is arranged, and to guy the wind energy installation ( 10 ) a guy apparatus that is changed as required automatically from an unstressed state which stabilizes the wind energy installation ( 10 ), and a wind energy installation having these features. | 5 |
BACKGROUND OF THE INVENTION
The promotion, planning, and execution required of organizers and sponsors for producing larger public gatherings such as concerts, state fairs, and the like typically involve the employment of numerous support services. An important one of those services provides for the seating of patrons. Typically, principal or supplementary seating, for example on a stadium field, often will require chairs numbering in the tens of thousands. That use of the chairs will be for a very limited interval of time, for example, musical presentations often being held for a single day.
To provide this seating, chairs of essentially universal, metal folding design are used. Having general dimensions of 171/2 in.×391/4 in. (44.5 cm×99.7 cm) and each weighing about 61/2 lbs the chairs, when folded, exhibit a repeating geometry, for example in the positioning of front legs in adjacency with back legs and the like. As a component of their design, the chain, when so folded, stack, exhibiting individual stack weights in internested relationship to enhance their transportability in larger numbers. Commercial entities engaged in the rental-supply of these chain traditionally have stacked them from floor to ceiling in tractor-trailer rigs having conventional box bed trailers. Regulatory limitations, of course, are imposed upon the size (height and width) and gross weight of these rigs, for example, a limitation in the latter regard typically being about 80,000 pounds.
Procedures carried out in supplying the chairs to a user site are quite labor intensive and, at times, hazardous. Generally, a tractor-trailer rig carrying the stacked chairs is driven to an unloading location adjacent the site. Labor then is required to unload the chairs onto pallets or the equivalent positioned reasonably adjacent the trailer. Should the tractor-trailer rig have encountered a steep grade just before or upon reaching the site, the stacked chair load may have shifted to lean against the rear doors. This hazardous condition must be corrected by reshifting the load, for example, by driving the tractor trailer rig to a downward grade.
Upon unloading and stacking chairs upon pallets or, very often, conventional sheets of plywood mounted upon some form of low standoff, they are moved by forklift trucks to the edge of the user site, for example, next to a stadium field. This movement also can be hazardous should the forklift trucks encounter unlevel or hilly terrain. In the latter regard, should the load tip, it may be lost or, at best, the number of chairs to be carried per trip with the forklift truck becomes limited. The chairs then are positioned at their intended location by the labor crews.
Many concerts or similar public affairs extend to late hours. Thus, the chair moving crew again is called upon to essentially reverse the above procedure. In this regard, the chairs are folded and stacked at the side of the field upon pallets or the ubiquitous sheets of plywood. Forklifts then are called upon to move the chairs to a location adjacent the trucks. The chairs then are unloaded from the pallets and are hand stacked in the trailers. However, a next procedure is required at this point, the chairs must be counted as each stacking course is completed across the widthwise extent of the trailer. All of these activities occur late at night under highly undesirable labor conditions. Leaving the chairs upon the pallets until morning generally is found to be unacceptable, inasmuch as the chairs are subject to theft.
SUMMARY
The present invention is addressed to a rack apparatus employed in the storing and transporting of a multitude of folding chairs. The apparatus is structured having a rigid frame with a base and upstanding members mutually configured and arranged to define a plurality of chair aligning and retaining bays. Each of these bays is generally accessible for chair insertion and removal from the sides and top of the apparatus. The dimensions of the frame are selected with respect to both the width, the height, and stack height of folding chairs and further with respect to the width of the trailer component of a tractor-trailer rig. Generally, that trailer component will be of a flat-bed variety.
With the rack arrangement, a substantial savings is realized in the labor requirements otherwise required for unloading and set-up as well as for removal and reloading of chairs at a site. In this regard, the chair loaded racks are removed directly from flat-bed truck trailers by forklift trucks and transported directly to the set-up site. Thus, there is eliminated the substantial labor heretofore expended in hand unloading the chairs from a trailer onto pallets for forklift pick-up and transport. Of course, the hazards associated with hand unloading at the trailer also are avoided. Because the stacked chairs are contained in alignment by the rack structures, the hazards otherwise encountered in moving the chairs over hilly terrain using forklift trucks are avoided.
Through the use of simple containment components, the chairs may be loaded upon the racks adjacent the performing site and left overnight without undue fear of theft. Thus, the labor effort required in reloading the tractor-trailer may be carded out a next day with refreshed labor crews. The recovery of the chairs from the site also is achieved with substantial labor savings. Once the chairs are stacked within the bays of the rack frames, forklift trucks again move the frames to the trailers and position them thereon. Counting of the chairs is greatly simplified, a verification that all chairs are stacked in the same direction only being required, inasmuch as a predetermined number of chairs will be located within a fully loaded chair retaining bay. Labor requirements further are substantially reduced in that the hand reloading and stacking of the chairs within a box wailer is eliminated.
Another feature of the invention provides a system for retaining and transporting a multitude of foldable stackable chairs, each having a back with mutually oppositely disposed upper curved comers and, when folded, two, oppositely disposed, paired front and rear leg ends positioned in adjacent, offset relationship to define an outwardly opening notch, the chairs generally exhibiting constant widthwise, lengthwise, and stack height dimensions when folded. A rack apparatus including a base component is provided having a widthwise base extent of dimension corresponding substantially with the chair lengthwise dimension and extending between substantially parallel first and second longitudinal edges and having a select lengthwise base extend along a longitudinal axis. A first linear array of paired, upstanding chair leg alignment stanchions of predetermined length is provided, each having a base portion fixed to the base component at the first longitudinal edge and extending from the base portion to a top portion. Each pair of the chair leg alignment stanchions has inwardly disposed first alignment surfaces along the predetermined height thereof which slidably receive a corresponding oppositely disposed outwardly opening notch of a given chair when folded to effect one retention of that given chair in alignment for stacking. A second linear array of paired, upstanding chair back alignment stanchions of the predetermined height is provided, each of the chair back alignment stanchions having a base portion fixed to the base component at the second longitudinal edge thereof and extending from that base portion to a top portion. Each pair of the chair back alignment stanchions is located in substantial alignment with each pair of the first linear array and each pair thereof has at least one inwardly disposed second alignment surface configured, and located to slidably align for stacking the back upper curved comers of the given chair when an outwardly opening notch thereof is slidably received at one of the first alignment surfaces.
Another feature of the invention provides a system for transporting stackable chairs utilizing a tractor trailer rig having a flat bed trailer of predetermined load supporting width for supporting a load maximum height. The system comprises a plurality of foldable, stackable chairs, each having a back with mutually, oppositely disposed upper curved corners and, when folded, two, oppositely disposed, paired front and rear leg ends positioned in adjacent, offset relationship to define an outwardly opening notch, the chairs generally exhibiting to principal dimensions when folded including widthwise and lengthwise dimensions, and having a stack height dimension when folded. A rack apparatus is provided including a base frame formed as a rectangle with four comers, having a lengthwise side extent and a widthwise side extent, each of the side extents corresponding with an integer multiple of a unique one of the chair principal dimensions. Four upstanding posts of predetermined height are provided, each having a post base portion fixed to the base frame at one comer and extending upwardly to a top portion and defining with the base frame a volume providing for a predetermined number of mutually adjacent bays each retaining stacked chairs and being of bay height corresponding with the predetermined height and bay widthwise extent corresponding with the chair widthwise principal dimension. A first plurality of upstanding chair leg alignment stanchions of predetermined height is provided. These stanchions have base portions fixed to the base frame at spaced, bay defining positions and extend from the base portions to top portions. Each additionally has inwardly disposed first alignment surfaces along the predetermined height slidably receiving the outwardly opening notches of chairs when folded and stacked in two mutually adjacent bays to effect a retention of the chairs in stacked alignment within the bays. A second plurality of upstanding chair back alignment stanchions of the predetermined height is provided. These back alignment stanchions have base portions fixed to the base frame at spaced bay defining positions. The chair back alignment stanchions extend from the base positions to top portions and each is aligned with a corresponding one of the chair leg alignment stanchions to define a bay and each has inwardly disposed second alignment surfaces aligning the back upper curved comers of the chairs when folded and stacked.
As a further feature, the invention provides a method for transporting a multitude of foldable, stackable chairs to the location of a public gathering, each chair having a back with mutually oppositely disposed upper curved corners and, when folded, oppositely disposed, paired front and rear leg ends positioned in adjacent, offset relationship to define an outwardly opening notch, the chair generally exhibiting two principal dimensions when folded, including widthwise and lengthwise dimensions and having a stack height dimension when folded, comprising the steps of:
providing a rack apparatus including:
a base frame formed as a rectangle with four corners, having a lengthwise side extent and a widthwise side extent, each side extent corresponding with an integer multiple of a unique one of the chair princpal dimensions,
four upstanding posts of predetermined height, each having a post base portion fixed to the base frame at one corner and extending upwardly to a top portion and defining with the base frame a volume providing for a predetermined number of mutually adjacent stacked chair retaining bays of bay height corresponding with the predetermined height and bay widthwise extent corresponding with the chair widthwise principal dimension,
a first plurality of upstanding chair leg alignment stanchions of predetermined height, having base portions fixed to the base frame at spaced bay definign positions and extending from the base portions to top portions, each having inwardly disposed first alignment surfaces along the predetermined height configured to slidably receive the outward opening notches of chairs, when folded and stacked into mutually adjacent bays to effect the retention of the chairs in stacked alignment within the bays, and
a second plurality of upstanding chair back alignment stanchions of the predetermined height, having base portions fixed to the base frame at spaced, bay-defining positions, the chair back alignment stanchions extending from the base portions to top portions, each being symmetrically aligned with a corresponding one of the chair leg alignment stanchions to define the bay, and each having inwardly disposed second alignment surfaces configured and located to slidably align for stacking the back upper curved corners of the chairs, when folded;
stacking a plurality of the chairs within each adjacent bay in a manner wherein the outwardly opening notch of each chair is in slidable engagement with one of the first alignment surfaces, and each chair back upper curved corner is in slidable engagement with one of the second alignment surfaces;
loading the rack apparatus upon the vehicle;
transporting the loaded rack apparatus to the vicinity of the location with the vehicle and unloading the rack apparatus thereat; and
transporting the unloaded rack apparatus to the location and removing the stacked chairs therefrom.
Other objects of the invention will, in part, be obvious and will, in part, appear hereinafter.
The invention, accordingly, comprises the apparatus possessing the construction, combination of elements, and arrangement of parts and method which are exemplified in the following detailed disclosure.
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an assemblage of stacked rack components according to the invention;
FIG. 2 is a perspective view of one embodiment of rack apparatus according to the invention;
FIG. 3 is a side view of the rack apparatus of FIG. 2;
FIG. 4 is a sectional view taken through the plane 4--4 in FIG. 3;
FIG. 5 is a sectional view taken through the plane 5--5 shown in FIG. 3;
FIG. 6 is a partial sectional top view showing an alignment feature of the invention;
FIG. 7 is a side view of another embodiment of a rack apparatus according to the invention;
FIG. 8 is a sectional view taken through the plane 8--8 shown in FIG. 7;
FIG. 9 is a sectional view taken through the plane 9--9 shown in FIG. 7;
FIG. 10 is an alternate arrangement showing bay geometry for a rack apparatus according to the invention;
FIG. 11 is another alternate geometry showing bay arrangement for a rack apparatus according to the invention;
FIG. 12 is a side view of a flat bed trailer upon which rack assemblages according to the invention are loaded; and
FIG. 13 is a back view of the trailer of FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
The rack apparatus of the invention serves both to facilitate the storing of folded chairs as well as their transportation to a performance site. Referring to FIG. 1, a pictorial representation is provided showing an assemblage 10 of folding chair retaining racks. This assemblage is formed of a plurality of rack components such as represented at rows of three vertically stacked racks as at 12-18. Each of the racks within the stacks 12-18 as well as those within a second grouping 20 positioned behind racks 12 and 18 are accessed by forklift trucks. Such forklift trucks insert the fork components thereof within and through guide straps as shown at levels 22-24 for elevating the racks at their bases and moving them as desired. Similarly, access to the racks is provided from the adjacent sides thereof as represented at guide strap rows or levels 26, 27, and 28. The assemblage 10 additionally depicts the racks as being filled with folded chairs, those folded chairs being within discrete bays, for example at 30-34 in the uppermost corner rack. The stacking alignment arrangement for the racks shown is one wherein the corners are configured having male and female sliding and mating components. In a preferred rack base component arrangement, an alignment system and tube-form base frame will be seen to be employed for the purpose of maximizing the number of chairs to be contained within a limited rack height.
Referring to FIG. 2, a discrete rack apparatus of the variety represented at the assemblage 10 is shown in perspective detail at 40. The apparatus 40 is seen to be formed having a base component or frame represented generally at 42. The base frame 42 is seen to be formed of longitudinal box beam members 44 and 46 and similarly dimensioned rigid widthwise end box members 48 and 50. Members 44 and 46 are united with beams 48 and 50 at four comer posts or comer stanchions 52-55. Additional bracing is provided for the base frame 42 by cross beams 58 and 59 to which are connected longitudinal bracing beams 60 and 61 extending, respectively, to end members 48 and 50. A downwardly depending forklift guide strap is connected as at 64 and 66 to the base component 42 at respective frame members 48 and 50. Similarly, forklift guide straps as at 68 and 70 are coupled to the respective box beam components 44 and 46 of base 42. It may be observed that the lower flat surfaces of these guide straps 64-70 are ground engaging and serve as the full ground support for the apparatus 40.
Looking additionally to FIG. 3, positioned between the comer stanchions or posts 53 and 54 is a linear array 72 of upstanding chair leg alignment stanchions 74-77. The base portions of these stanchions 74-77 as well as the base portions of comer stanchions or posts 53 and 54 are rigidly coupled to the base frame 42 by welding or the like and extend upwardly a predetermined height to an upper bar support 80. The figures also reveal that each comer of the frame 42 as presented at the bottom portions of comer stanchions or posts 52-55 is formed having four lower stacking connectors. Two of these male connectors are seen at 82 and 83 in FIG. 3 with respect to posts 53 and 54. Identical male connectors are provided at the opposite side of frame 42, one of which is shown at 84 in FIG. 2. It may be observed in FIG. 3 that these male connectors as at 82 and 83 are retained above ground level by the guide straps 64, 66, 68, and 70. To accommodate for rack upon rack stacking, note that the top of each of the posts, for example as seen in FIG. 3 in connection with posts 53 and 54, is extended upwardly a compensating amount above the upper support bar as at 80. This compensation distance is represented in FIG. 3 at 86 and 87 for the case of respective posts 53 and 54. A similar compensating distance is provided at posts 52 and 55 as shown, respectively at 89 and 90 and illustrated in FIG. 2. Looking again to that figure, symmetrically aligned with and opposite to the array of chair leg alignment stanchions 72 is a corresponding array of chair back alignment stanchions represented generally at 92. These chair back alignment stanchions are formed having a rectangular cross section in the same manner as the stanchions of array 72, however, the stanchions, as seen at 94-97 are attached at their base portions to box beam 44 such that they are aligned at about 45° with respect to the lengthwise extent of the beam 44 or the longitudinal axis 110 of the rack apparatus 40 (FIG. 4). Stanchions 94-97 extend upwardly a predetermined height derived in conjunction with array 72 to an upper support retainer bar 100 having a flange portion 162 at the uppermost surface thereof which extends over the interior of the rack assembly 40. The structural aspects of rack apparatus 40 are completed by upper cross supports 102 and 104 to constitute an upper frame. In this regard, support 102 extends between and is fixed to and supports or laterally stiffens posts 52 and 53, while support 104 is fixed to and supports or laterally stiffens posts 54 and 55.
Referring to FIG. 4, the longitudinal axis of the rack apparatus 40 is depicted at 110. This axis 110 is seen to extend across five, chair retaining bays as are represented at 112-116. The technique of alignment of stacked, folded chairs is represented in the figure by the phantom representation of folded chain 118 and 120. Chairs 118 and 120 are identical and, when folded as illustrated in connection with chair 118 are seen to comprise a seat 122, a chair back 124, and interconnecting tubular framework represented in general at 126. Looking additionally to FIG. 6, it may be observed that the framework 126 of folded chair 18 presents, oppositely disposed paired front and rear leg ends at each chair side. As seen in FIG. 6, one such pair of leg ends is represented at 128 and 130. When the chair 118 is folded, these legs 128 and 130 are positioned in adjacent, offset relationship to define an outwardly opening notch 132. FIG. 6 shows this notch 132 being located in adjacency with alignment surfaces 134 and 136 of chair leg alignment stanchion 74 to appropriately align a comer of the chair 118 within the bay 112. A similar alignment occurs in conjunction with the oppositely disposed leg ends of chair 118 in conjunction with alignment surfaces of comer stanchion or post 53 as seen in FIG. 4. Chair leg alignment stanchion 74 also performs an aligning function in conjunction with a corresponding outwardly opening notch 138 defined by paired front and rear leg ends 140 and 142 of adjacent chair 120. In this regard, note that alignment surfaces 134 and 144 of chair leg alignment stanchion 74 serve this alignment function.
Now looking to the upper side of folded chair 118, it may be seen in FIG. 4 that it is formed having upwardly disposed curved comers 146 and 147. Similarly, chair 120 is seen to have upwardly disposed curved comers 148 and 149. The chair curved end 147 of chair 118 is positioned in slidable tangential adjacency with one alignment surface 152 of chair back alignment stanchion 94. Similarly, the curved component 148 of chair 120 is in sliding tangential adjacency with the alignment surface 154 of stanchion 94. A comer of post 52 serves the same function with respect to comer 146 of chair 118.
With the arrangement shown, for each of the bays 112-116, an alignment is provided with respect to the four comers of the chairs as at 118 and 120. These chairs all have substantially constant principal widthwise and lengthwise dimensions which, in turn, dictate the dimension of chair retaining bays 112-116. Accordingly, a widthwise extent of a given bay for the rack apparatus 40 will correspond with the widthwise dimension of the chairs. As is illustrated later herein, that widthwise extent also determines the length along axis 110 of apparatus 40 along with a consideration of the corresponding width of a conventional flat bed trailer of a tractor trailer rig.
Chairs as at 118 and 120 additionally have a constant stacking height, for example of about 1 inch. Thus, the predetermined effective heights of the stanchions as at 74-77, 94-97, aid the comer stanchions or posts 52-55 is selected with respect to the number of chairs desired to be stacked within a given bay. Looking to FIG. 5, an array of stacked chairs is represented in general at 160 extending from the base frame or component 42 upwardly a predetermined height which is determined, as noted above by the stack height of the chairs and the restrictions on total transportation load weight and height as regulated by governmental entities. A maximum loaded weight may be, for example, 80,000 pounds. Rack apparatus 40, fabricated of 10 gauge steel will weigh, empty, about 300 pounds. The chairs, typically having folded dimension of 171/2"×391/4" weigh about 6.5 pounds a piece. The predetermined effective height of the apparatus 40 will vary with trailer heights. Interstate highway regulations currently limit load or wailer top height to 13.5 feet. Considering this restriction and the variations in wailer heights, effective rack apparatus heights of 51 inches to 61 inches have been selected. Generally, one rack apparatus 40 will carry a total of 190 chairs, stacking 36 chairs within each of the five bays. This height also is selected so that the array of stacked folded chairs 160 may be secured in place such that the rack 40 may be left at a performance site overnight pending retrieval by a crew following a performance on a following day. Note in this regard that the upper support retainer bar 100 is configured having an inwardly extending flange portion 162 which extends over the upper or chair back frame or framework region of the chairs as represented in the figure at 164. Thus, the loading crew fills a given bay by stacking the chairs therein in slidable alignment provided by the alignment surfaces of the chair leg alignment stanchions and the chair back alignment stanchions. After a predetermined number of chairs as established by the constant chair stacking height has been stacked, the last chair to be positioned will abut against the inner surface of inwardly extending flange portion 162 of upper support retainer bar 100. Correspondingly, the oppositely disposed chair leg end components as described in connection with FIG. 6 will be positioned adjacent the vertically oriented upper support and retainer bar 80. To lock the assemblage into place, an elongate retainer bar 166 is locked down over the chair end components at the top of the stacked array within all bays. When properly, uniformly stacked, only a constant, fixed number of chairs will fit within a bay. Thus, the chair counting procedure heretofore required during track loading can be eliminated or substantially minimized.
Returning to FIG. 2, this retainer bar 166 is revealed in conjunction with a rack apparatus orientation representing a chair unloading mode. In this regard, the retainer bar 166 is seen to have two downwardly depending and vertical support and alignment bars 168 and 169 which slide within the interior cavities of respective stanchions 74 and 77. One such inner cavity, for example, with respect to stanchion 74, is revealed at 172 in FIG. 6. The retainer bar 166 is retained in the orientation shown at FIG. 2 for unloading by a pin 174 carried on the apparatus 40 with a small chain 176, and inserted through mating holes or bores within stanchion 74 and sliding bar 168. The bar 166 is moved downwardly to the orientation shown in FIG. 5 by removing the pin 174. As the bar 166 descends, an annular opening within a downwardly depending locking tab 178 descends into alignment with an opening within a corresponding locking tab 180 depending downwardly from retainer bar 80. A simple padlock then may be employed to lock the assemblage into place. Pin 174 and chain 176 are revealed at a heightened degree of clarity in FIG. 3 in conjunction with the pin opening formed within stanchion 74 for the purpose of receiving pin 174.
Design criteria for the rack assemblies of the invention are concerned with portability such that they may be moved by a forklift truck with safety and ease; maximized chair retention to take full advantage of moving as many chairs as possible with a given rack; security for overnight storage at a performance site; and assurance for many applications that no damage will be done to the grass or turf at the performance sites by the racks themselves as they are moved into positions adjacent the location of performance. In this regard, it is desirable that the racks not be positioned, for example, on the turf of a football field. However, occasions may arise where that situation will occur inadvertently.
FIGS. 7, 8, and 9 reveal another embodiment of the invention further improving the criteria of maximized chair retention for a given rack apparatus height and preservation of performance locale turf. In the figures, a rack apparatus is represented generally at 190 having a base frame or component 192. The figures reveal that the base frame 192 is formed of two elongate rectangular rigid tubes 194 and 196 which have flat ground engaging surfaces as are seen, respectively, in FIG. 9 at 198 and 200. That figure additionally reveals that the tubes 194 and 196 are open at their ends such that they may receive the fork tines of a forklift truck. The rectangular shape of the base frame 192 is developed through the utilization of two additional and similarly dimensioned rectangular rigid tubes seen in FIG. 8 at 202 and 204. FIG. 9 reveals that the lower surface of tube 202 at 206 is coextensive or coplanar with the lower surfaces 198 and 200 of respective longitudinal tubes 194 and 196. Tube 204 is similarly symmetrically positioned within the base frame 192. Accordingly, the weight of rack apparatus 190 is distributed over a substantially greater ground engaging surface, such that turf damage is substantially avoided when the devices are improperly positioned on such turf.
Tubes 202 and 204 are hollow and rigidly attached to the longitudinal tubes 194 and 196. Their effective length is coextensive with the widthwise dimension of the base frame 192 by virtue of openings cut in the inwardly and outwardly disposed side surfaces of the latter tubes 194 and 196. These openings are in alignment with the interiors of tubes 202 and 204 such that interior channels are developed which are positioned and dimensioned to receive the tines of a forklift truck. Such openings provide access to the tubes and for insertion of the fork component with respect to one side are shown in FIG. 7 at 208 and 210 providing channel definition as communication with respective tubes 202 and 204. Base frame 192 is completed with additional structural members including cross members 212 and 214 which correspond, respectively, with cross beams 48 and 50 as seen in FIG. 4. Additionally, the frame includes longitudinal bracing beams 216 and 218 corresponding, respectively, with beams 60 and 61 as seen in FIG. 4.
The bay defining structure or geometry of the rack apparatus 190 is the same as that for the rack assembly 40. In this regard, FIG. 8 reveals the provision of four upstanding corner posts or alignment stanchions 220-223 corresponding with respective corner posts 52-55 of apparatus 40. Positioned between posts or stanchions 221 and 222 are upstanding chair leg alignment stanchions 225-228 which extend to an upper support retainer bar 230 as seen in FIGS. 7 and 9 and which corresponds to the support bar 80 shown in FIG. 5. As before, the support bar 230 as well as stanchions 225 and 228 are configured for association with a securing retainer component as described in FIG. 2 at 166 and shown at 232 in FIG. 9. The same form of chair securement is provided including a loading mode orientation for the component 232 involving, for example, a pin 234, retaining chain 236, and pin opening 238 as seen in FIG. 7 which are identical to the corresponding components 174, 176, and 182 seen in FIG. 3. In similar fashion, a downwardly depending locking tab is seen at FIG. 9 at 240 as extending from component 232. This locking tab moves into mating relationship with downwardly extending tab 242 as seen in FIG. 7. Tab 242 corresponds with tab 180 as described in connection with FIG. 3, while tab 240 corresponds with tab 178 as described in FIG. 2. Cross bars extend across the upper portions of the posts 220 and 221 and posts 222 and 223. One such cross bar is shown at 244 in FIG. 9.
Returning to FIG. 8, rack apparatus 190 also includes an array of four upstanding chair back alignment stanchions 246-249 which are regularly spaced between posts 220 and 223. Stanchions 246-249 are configured identically with those described in connection with FIG. 3 at 94-97 and carry out the same chair back alignment feature as represented in phantom by the association thereof with a chair 252. FIG. 9 shows that the expanding chair back aligning stanchions 246-249, as well as the corresponding comer posts 220 and 223 extend to an upper support retainer bar 254 having an inwardly extending flange 256. Flange 256 as well as the bar 254 correspond, respectively, with the components 100 and 162 described in connection with FIG. 5.
Thus configured, the rack apparatus 190 provides for five adjacent chair stacking and aligning bays 260-264 which are positioned in mutual adjacency and oriented perpendicularly to a longitudinal axis 266 corresponding with the lengthwise extent of apparatus 190.
To provide for rack upon rack stacking of the rack apparatus 190, the bottom fiat rectangular surface serves as one component for connection. This flat rectangular lower portion of the base frame 192 is retained in alignment upon the top frame components of a lower disposed rack by upstanding tags seen at 268 in FIGS. 7 and 9 which are disposed about the upper support components of the apparatus 190. Thus, a forklift apparatus is employed to lift one rack using the rigid tube base structure and position it upon the next adjacent rack with the tabs 268 providing for final alignment such that load transfer is symmetrically downwardly directed from one rack to the next.
In addition to providing for improved turf protection at a performance site, the rack apparatus embodiment 190 also permits the loading of a greater number of chairs, for example two additional chairs per bay, while maintaining the same height as the embodiment at 40. This represents a significant enhancement when considering the number of chairs carried by a single trailer.
The base structuring shown in the embodiments of FIGS. 1-9 is one wherein the bays are aligned in parallel and transversely to the longitudinal axis of the rack apparatus. Other bay geometries will occur to the designer. Looking to FIG. 10, another bay geometry is represented in general at 280 as including four bays 282-285 which are arranged such that the principal longitudinal dimension of the folded chairs will be parallel with the longitudinal axis 288 of the assembly and one bay 286 is arranged transversely thereto.
Looking to FIG. 11, still another arrangement of bays is represented at 290. In arrangement 290, three bays 292-294 are arranged transversely to the longitudinal axis 296 of the apparatus. To complete the assembly, two bays as 298 and 299 are located intermediate bays 293 and 294 and are arranged such that the principal longitudinal dimension or height of the chairs are parallel with the central longitudinal axis 296.
Referring to FIG. 12, a representation of the flat bed trailer 300 of a tractor trailer rig is illustrated as being positioned upon a surface 302. Upon the trailer 300 there are stacked rack apparatus according to the invention and represented at 304. It may be observed that two rack levels as at 306 are provided, the thus stacked rack pairs being retained upon the bed of the trailer 300 by straps as at 310-318. As is apparent, these individual rack components of the assemblage 304 are readily loaded and removed by a forklift truck. The carrying of assemblage 304 upon the trailer 300 is subject to the limitations of height, h, as represented in the drawings and by the overall weight of the assemblage. Thus, the selection of the predetermined height of the rack is predicated, in pan, upon the available height, h, for transportation. It is desirable to maximize the number of chairs carried on the trailer 300, thus the value of the rack apparatus 190 embodiment, providing for the stacking of a greater number of chairs per bay becomes evident.
Looking additionally to FIG. 13, the trailer 300 and rack assemblage 304 again is illustrated as a rear view. Here, the available loading width, w, of the trailer 300 is considered additionally in determining the lengthwise extent of the chair racking devices. Generally, the number of bays will be 5 for conventional flat bed trailers.
Since certain changes may be made in the above described system and apparatus without departing from the scope of the invention herein involved, it is intended that all matter contained in the description thereof or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | Rack apparatus for removably retaining and transporting a multitude of folded stack and stackable chairs is described. The apparatus includes a base frame upon which are mounted upstanding stanchions with alignment surfaces providing for the lined stacking of chairs in a sequence of chair stacking bays. The chairs may be locked within fully filled bays and the entire apparatus is movable with a conventional forklift truck into rack upon rack stacking orientations on the bed of a flat bed trailer for transportation to a site or for purposes on site and warehousing storage. | 1 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to cryogenic refrigerators, in particular, Gifford McMahon (GM) refrigerators, GM type pulse tube refrigerators, and Solvay refrigerators. Coldheads of such cryogenic refrigerators include a valve mechanism, which commonly consists of a rotary valve disc and a valve seat. There are discrete ports, which, by periodic alignment of the different ports, allow the passage of a working fluid, supplied by a compressor, to and from the regenerators and working volumes of the coldhead.
[0002] GM and Solvay type refrigerators use compressors that supply gas at a nearly constant high pressure and receive gas at a nearly constant low pressure. The gas is supplied to a reciprocating expander that runs at a low speed relative to the compressor by virtue of a valve mechanism that alternately lets gas in and out of the expander. U.S. Pat. No. 3,119,237 to Gifford shows an early pneumatically driven GM expander and a multi-ported rotary spool valve to control gas flow to the regenerator out of phase with gas flow to the drive piston. In a subsequent U.S. Pat. No. 3,205,668, Gifford discloses a multi-ported rotary disc valve that uses the high to low pressure difference to maintain a tight seal across the face of the valve. He states that this type of valve is superior to the spool type valve because the leak rate is lower, even after it has run a long time and has experienced some wear. This type of valve has been widely used in different types of GM refrigerators as shown for example in Longsworth U.S. Pat. No. 3,620,029, and Chellis U.S. Pat. No. 3,625,015.
[0003] This type of valve has the disadvantage of requiring an increased amount of torque as the diameter is increased to accommodate larger ports. Lobb, U.S. Pat. No. 4,987,743 describes a means of reducing the force on the face of the valve disc by having a plug in the back of the valve disc that is attached to the motor shaft. High pressure gas on the back side of the plug and low pressure gas in the cavity between the face of the plug and the central part of the back of the valve disc puts an axial load on the motor bearings, but reduces the force on the face of the valve disc. This results in a lower torque being required to turn the valve disc. The direction of force on the motor shaft is towards the valve seat.
[0004] Gifford also conceived of an expander that replaced the solid displacer with a gas displacer and called it a “pulse tube” refrigerator. This was first described in Gifford U.S. Pat. No. 3,237,421 which shows a pulse tube connected to valves like the earlier GM refrigerators. It also shows a pulse tube expander connected directly to a compressor so it pulses at the same speed as the compressor. This is equivalent to a Stirling cycle refrigerator.
[0005] Early pulse tube refrigerators were not efficient enough to compete with GM type refrigerators. A significant improvement was made by Mikulin et al., as reported in 1984, (E. I. Mikulin, A. A. Tarasow and M. P. Shkrebyonock, ‘Low temperature expansion (orifice type) pulse tube’, Advances in Cryogenic Engineering, Vol. 29, 1984, p. 629) and significant interest ensued in looking for further improvements. Descriptions of major improvements since 1984 can be found in S. Zhu and P. Wu, ‘Double inlet pulse tube refrigerators: an important improvement’, Cryogenics, vol. 30, 1990, p. 514; Y. Matsubara, J. L. Gao, K. Tanida, Y. hiresaki and M. Kaneko, ‘An experimental and analytical investigation of 4K (four valve) pulse tube refrigerator’, Proc. 7 th Intl Cryocooler Conf., Air Force Report PL-(P-93-101), 1993, p166-186; S. W. Zhu, Y. Kakami, K. Fujioka and Y. Matsubara, ‘Active-buffer pulse tube refrigerator’, Proceedings of the 16 th Cryogenic Engineering Conference, 1997, p. 291-294; and J. Yuan and J. M. Pfotenhauer, ‘A single stage five valve pulse tube refrigerator reaching 32K’, Advances in Cryogenic Engineering, Vol. 43, 1998, p. 1983-1989.
[0006] All of these pulse tubes can run as GM type expanders that use valves to cycle gas in and out of the pulse tube, but only the single and double orifice pulse tubes have been run as Stirling type expanders. Stirling type pulse tubes are small because they operate at relatively high speed. The high speed makes it difficult to get to low temperatures so GM type pulse tubes running at low speed are typically used for applications below about 20 K. It has been found that best performance at 4 K has been obtained with the pulse tube shown in FIG. 9 of Gao, U.S. Pat. No. 6,256,998. This design has six valves which open and close in the sequence shown in Gao's FIG. 11.
[0007] In order to keep the valve disc in contact with the valve seat, in most of the prior art, the valve disc is located in a chamber, which is filled with high-pressure working fluid. Usually, this chamber is connected to the supply side of a compressor. This is shown in Gifford U.S. Pat. No. 3,205,668, Longsworth U.S. Pat. No. 3,620,029, Chellis U.S. Pat. No. 3,625,015, and Lobb U.S. Pat. No. 4,987,743.
[0008] Since the valve disc is in the chamber connected to the supply side of the compressor, the wear dust from the valve disc tends to be blown into the cold head itself, which degrades performance. The pulse tube refrigerator is more sensitive to the dust than a conventional GM refrigerator because this dust tends to stick on the surface of the needles which are used to adjust the opening of the orifices at the warm end of the pulse tube, or to accumulate in the orifices and flow passages. The performance of a pulse tube refrigerator is sensitive to the opening of the orifices, thus it is desirable to keep them free of dust. The tendency to blow dust into the ports on the valve disc is due to high pressure gas being on the outside blowing dust radially inward toward the low pressure regions in the center of the valve disc.
[0009] It has been found that less dust from the wear of the valve disc collects in the warm end of the regenerator and pulse tube orifices if the flow through the valve disc is reversed. That is to have high-pressure gas enter through the center of the valve disc face and discharge radially to low pressure on the backside of the valve disc. Asami et al. U.S. Pat. No. 5,361,588 shows an arrangement for a GM refrigerator where the high-pressure gas from the compressor acts against a valve seat to push it into the face of a rotary valve. A bearing is shown to hold the valve disc against the axial force of the valve seat, rather than transferring it as an axial load on the motor shaft. The flow of gas in this arrangement is reversed from the conventional arrangement shown in previous patents. Conceptually the conventional valve disc shown in FIG. 7 of Longsworth U.S. Pat. No. 3,620,029 could have the flow reversed if the spring that is shown would apply enough force to keep the valve disc seated.
[0010] It would be desirable to provide a valve unit that reduces the amount of dust blown into the cold heat and at the same time reduces wear on the valve and requires lower torque.
SUMMARY
[0011] A rotary valve unit has now been developed that is significantly different than the rotary valve described in Lobb U.S. Pat. No. 4,987,743, and which reduces the torque required to turn the valve disc, and the amount of wear dust that is blown into the cold head. This valve unit uses differential gas forces to keep the valve disc in contact with the valve seat, which enables larger diameter valve discs to be designed and utilized for multi-ported pulse tubes that have less force on the face of the valve disc. The reduced force on the face of the valve disc results in reduced torque and reduced wear rate.
[0012] This invention provides an improved means of reducing the torque required to turn a rotary disc valve that seals multiple ports by maintaining a net force that keeps the face of the valve disc in contact with the seat. This force is reduced relative to conventional valve discs that rely on the force due to high-pressure acting on the back of the valve disc being greater than the force on the face of the valve disc because it has low-pressure gas in the center. This invention provides means to reduce the axial sealing force by having gas at two different pressures acting on two different surfaces in the valve assembly. The sealing force is in a direction that would cause the valve disc to lift off the seat but an axial force against the motor shaft or a separate bearing restrains it.
[0013] It is possible to have high-pressure gas in the center of the valve seat and low-pressure gas on the outside of the valve disc. This provides a major advantage, especially in a multi-ported pulse tube, of significantly reducing the amount of dust, from the wear of the valve disc, which is blown into the pulse tube. Having the high pressure in the center of the valve disc face and low pressure on the outside results in most of the dust being blown directly to the low-pressure space and never entering the pulse tube. Reducing the sealing force also results in less dust being generated and longer valve disc life.
[0014] This invention includes having two different surfaces with two different pressures that are located either in the rotating valve disc or in the stationary valve seat. The gas pressures that must be different can be selected from the high-pressure, low-pressure, pulse tube buffer pressure, atmosphere, pressure in a sealed volume, or a pressure that is controlled between the high and low pressures in the compressor. It is also possible to bias the force mechanically, such as by means of a spring.
[0015] Applying the principal of differential force to push the valve seat against the valve disc can be applied to the conventional arrangement of having high-pressure gas out side the valve disc and low-pressure gas in the center of the valve face. This reduces the torque required to turn the valve disc but does not reduce the fraction of dust that is generated from getting into the pulse tube. Most embodiments of this invention differ from Lobb U.S. Pat. No. 4,987,743 in that the force on the motor shaft is not in the direction toward the sealing surface, but is in the opposite direction. This not only enables a lot of the wear dust to be blown out, but also enables the use of a separate bearing to carry the axial load instead of the motor bearings. Reducing the amount of dust that enters a pulse tube also improves the temperature stability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a cross section of a valve assembly in accordance with the present invention in which small schematics of the compressor and a single stage double inlet pulse tube refrigerator are included to show the flow relations. Differential pressures in the valve disc create the sealing force;
[0017] FIG. 2 is a face profile of a valve disc forming part of the valve unit of FIG. 1 ;
[0018] FIG. 3 is a face profile of the valve seat forming part of the valve unit of FIG. 1 ;
[0019] FIG. 4 is a cross section of a second embodiment of a valve assembly in accordance with the present invention in which buffer gas from the pulse tube provides one of the sealing pressures.
[0020] FIG. 5 is a face profile of a valve disc forming part of the valve unit of FIG. 4 ;
[0021] FIG. 6 is a face profile of the valve seat forming part of the valve unit of FIG. 4 ;
[0022] FIGS. 7 and 8 are cross sections of third and fourth embodiments of valve assemblies in accordance with the present invention in which the differential sealing force is located in the valve seat;
[0023] FIGS. 9 and 10 are cross sections of fifth and sixth embodiments of valve assemblies in accordance with the present invention in which buffer gas from the pulse tube provides one of the sealing pressures, acting in the valve seat;
[0024] FIG. 11 is a cross section of a seventh embodiment of a valve assembly in accordance with the present invention in which the differential sealing force is located in the valve seat but gas flow is reversed from the previous embodiments;
[0025] FIG. 12 is a cross section of an eighth embodiment of a valve assembly in accordance with the present invention which is a variation of the seventh embodiment.
[0026] FIG. 13 is a cross section of a ninth embodiment of a valve assembly in accordance with the present invention which is a special case of the sixth embodiment in which buffer gas from the pulse tube provides the sealing pressure acting on one surface of the valve seat;
[0027] FIG. 14 is a cross section of a tenth embodiment of a valve assembly in accordance with the present invention which is a special case of the eighth embodiment in which buffer gas from the pulse tube provides the sealing pressure acting on one surface of the valve seat;
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention is applicable to any kind of refrigerator in which gas is cycled in and out of the expander by a valve unit, including G-M refrigerators, Solvay refrigerators, and G-M type pulse tube refrigerators. It is of particular value when applied to low temperature pulse tubes that have multi-stages and multi-ports.
[0029] FIG. 1 shows a cross section of valve assembly 29 along with small schematics of the compressor and a single stage double inlet pulse tube refrigerator to show the flow relations.
[0030] Valve unit 29 has a valve motor assembly 5 , a valve housing 7 and a valve base 17 , all of which are sealed by means of a variety of ‘O’-ring seals, and by bolts 1 . Inside the valve base and housing, there are various components. A valve seat 21 is held and sealed within the valve housing. A valve disc 4 is turned by valve motor 5 through a motor shaft 6 and a pin 3 passing through shaft 6 . Valve disc 4 is free to move axially relative to pin 3 . Valve disc 4 is in contact with valve seat 21 . Pin 3 also holds valve holder 2 which is sealed in valve disc 4 by an ‘O’-ring 9 . A spring 8 is used to keep valve disc 4 in contact with valve seat 21 when the refrigerator is off.
[0031] An outlet 10 is connected to the return side of compressor 20 through a gas line 18 . The supply side of compressor 20 connects to valve assembly 29 through the gas line 19 and an inlet 14 . Gas at high pressure then flows through channel 13 to the center of valve disc 4 .
[0032] FIG. 2 shows the gas flow cavities in the face of valve disc 4 . The cross section shown in FIG. 1 is noted by section arrows A-A in FIGS. 2 and 3 . High-pressure, Ph, gas from channel 13 is distributed in cavity 40 while channel 41 connects high-pressure gas to cavity 11 , FIG. 1 . Regions 12 that are under cut in the outer edge of valve disc 4 connect to low-pressure, Pl, gas that returns to the compressor. When it is operating, the wear on the engaging surfaces of the valve disc 4 and the valve seat 21 tend to be blown out from the high-pressure region in cavity 40 to the low-pressure region around the outer edge of valve disc 4 and cavities 12 .
[0033] FIG. 3 shows the face of seat 21 . Although not essential to an understanding of the invention, the nature of this porting will be briefly described with reference to FIGS. 1, 2 , and 3 . FIG. 1 shows a double inlet type pulse tube refrigerator driven by the invented valve unit. It consists of a regenerator 22 , a pulse tube 25 with warm end flow smoother 26 and cold end flow smoother 24 , a cold end heat exchanger 23 . A phase shifter, which includes a buffer orifice 27 , a double inlet valve 30 , and a buffer volume 28 . By rotating valve disc 4 against valve seat 21 by means of valve motor 5 and shaft 6 , holes 15 and 16 are alternately pressurized by gas flowing through slots 40 and depressurized by flow through cavities 12 . The porting shown in FIGS. 2 and 3 produce two complete cycles to pressurize and depressurize the pulse tube for every rotation of valve disc 4 . It is to be understood that the expander can be operated with one, or more than one, cycle per cycle of the rotary valve by properly arranging the supply and return porting on valve disc 4 and valve seat 21 . The discharge of flow from the expander into the motor housing has a tendency to blow wear dust out of the expander and thereby increases the reliability of the refrigerator.
[0034] The exterior surfaces of valve disc 4 and valve holder 2 are surrounded by low-pressure gas except for the surface of valve disc 4 that is in contact with valve seat 21 . The pressure across the face of valve disc 4 has gradients between the high pressure in slot 40 and the outer perimeter, which is at low pressure. The pressure distribution across the face of valve disc 4 changes as it rotates and alternately has high-pressure gas flow into port 15 then lets low-pressure gas flow out. The force required to have valve disc 4 seal against the face of seat 21 is greatest when it seals ports 15 against high-pressure gas, and is minimum when the face of valve disc 4 seals ports 15 against low-pressure gas. The force required to have a seal across the face of valve disc 4 is obtained by having the product of the pressures and areas on the distal side of valve disc 4 be greater than the product of the maximum average pressure on the face of valve disc 4 and the area of the face of valve disc 4 . This can be expressed in the form of an equation in which Ac is the area of the distal side of valve disc 4 in cavity 11 , As is the annular area of the distal side of valve disc 4 around Ac, Av is the area of the face of valve disc 4 , and Pv is tne average pressure acting on Av (both including the area and pressure of cavity 12 ), as
( Ac*Ph+As*Pl )> Av*Pv max Equation 1
[0035] The opposing force is transmitted to motor shaft 6 and puts an axial load on the motor bearings in the direction away from valve disc 4 . In practice the diameter of cavity 11 is adjusted by testing different sizes to see what gives the best balance between minimizing leakage and torque. Minimizing the torque also minimizes wear rate.
[0036] Although the expander shown in FIG. 1 is a single stage pulse tube, it is also possible to design the valve unit and porting so that it can be used to drive a multi-stage pulse tube with multiple control ports as shown for example in FIG. 9 of U.S. Pat. No. 6,256,998. By properly arranging the porting on the valve disc 4 and the valve seat 21 , and by arranging necessary passages to communicate with the warm end 26 of the pulse tube 25 , the invented valve unit can also be used to drive any type of pulse tube refrigerator, such as, orifice type, four valve type, active-buffer type and five-valve type. It must be pointed out that this valve unit can be used for other kinds of refrigerators, such as GM or Solvay types.
[0037] FIG. 4 shows another embodiment of the present invention in which gas from another part of the system is used to pressurize cavity 11 . In FIG. 4 like reference numerals denote like parts in FIG. 1 . Assuming that the pressure in cavity 11 is Pc then the criteria that has to be satisfied for sealing is,
( Ac*Pc+As*Pl )> Av*Pv max Equation 2
[0038] From equation 2 it is seen that Pc has to be large enough so the diameter required for cavity 11 is less than the diameter of valve disc 4 . FIG. 4 shows cavity 11 communicating with the buffer 28 , at pressure Pb, at the warm end of the pulse tube, through flow passages 100 , 110 and 120 . In a pulse tube refrigerator, the buffer has a pressure that is slightly above the average of Ph and Pl. It is also recognized that the pressure can be supplied by another means that controls the pressure between Ph and Pl at a value that minimizes the torque needed to turn valve disc 4 .
[0039] FIGS. 5 and 6 show the porting at the interface of valve disc 4 and valve seat 21 respectively of FIG. 4 . Arrows ‘B-B’ on FIGS. 5 and 6 denote the cross section shown in FIG. 4 . High-pressure gas flows through ports 13 in valve seat 21 and into cavities 50 in valve disc 4 . Gas that pressurizes cavity 11 in valve disc 4 flows from port 100 in the center of valve seat 21 through center port 120 in valve disc 4 .
[0040] FIG. 7 shows a third embodiment of this invention. In FIG. 7 , like reference numerals denote like parts in FIG. 1 . This embodiment incorporates the same principal of having two different pressures acting on two different surfaces to affect a sealing force between valve disc 34 and seat 33 . In this case valve disc 34 is fixed on motor shaft 6 and seat 33 has different gas pressures on two different surfaces to move it axially into contact with valve disc 34 .
[0041] The distal surfaces of valve seat 33 are separated into two regions. A gas tight seal 43 separates these two regions. The center region 39 having area Ac communicates with the supply side of the compressor 20 through channel 14 and gas line 19 . The shoulder region 31 having area As communicates with return side pressure Pl through channel 32 , outlet 10 and gas line 18 . A spring 8 is used to keep valve disc 34 in contact with valve seat 33 when the refrigerator is off, and to generate an initial force to seal valve seat 33 with valve disc 34 at startup. Valve disc 34 differs from valve disc 4 of FIG. 1 in that it does not have valve holder 2 , center hole 41 , or cavity 11 . Gas flow is the same.
[0042] The criteria for having enough force to have a seal on the face of valve disc 34 against seat 33 is similar to that given by equation 3 . Ac refers to the surface area at the end of seat 33 in cavity 39 , As refers to the annular area in shoulder cavity 31 , and Asa refers to the surface area on the face of valve seat 33 that is at the pressure that surrounds valve disc 34 . In this embodiment the pressure around valve disc 34 is Pl.
( Ac*Ph+As*Pl−Asa*Pl ) >Av* ( Pv max− Pl ) Equation 3
[0043] The fourth embodiment of this invention is shown in FIG. 8 where like reference numerals denote like parts in FIG. 7 . The basic components are similar to those in the valve unit in FIG. 7 except that the pressure exerted on area Ac in the center region 39 and on the shoulder surface As in cavity 31 are reversed. Center region 39 communicates with low pressure PI through hole 32 while shoulder region 31 communicates with Ph through channel 14 and gas line 19 . The criteria for having a sealing force is,
( Ac*Pl+As*Ph−Asa*Pl )> Av* ( Pv max− Pl ) Equation 4
[0044] FIG. 8 shows the option of having a bearing 36 between the distal side of valve disc 34 and the face of motor 5 . Bearing 36 carries the axial force, which is equal to the left hand side of equation 4 , rather than one of the motor bearings.
[0045] FIG. 9 shows a fifth embodiment of the present invention in which gas from another source is used to pressurize shoulder cavity 31 . In FIG. 9 like reference numerals denote like parts in FIG. 7 . Assuming that the pressure in cavity 31 is Ps then the criteria that has to be satisfied for sealing is,
( Ac*Ph+As*Ps−Asa*Pl )> Av* ( Pv max− Pl ) Equation 5
[0046] Unlike embodiment 2 shown in FIG. 4 , Ac can be larger than Av because the diameter of seat 33 does not have a set limit. This means that the value of Ps can be lower and still have a seal. FIG. 9 shows cavity 31 communicating with buffer 28 , at pressure Pb, through flow passage 110 .
[0047] The sixth embodiment of this invention is shown in FIG. 10 , where like reference numerals denote like parts in FIG. 9 . The basic components are similar to those in the valve unit in FIG. 9 except the pressures in center region 39 and shoulder region 31 are reversed. FIG. 10 shows Pc being provided by Buffer gas at pressure Pb which communicates with center region 39 through channel 200 . The relation required for a sealing force is,
( Ac*Pc+As*Ph−Asa*Pl )> Av* ( Pv max− Pl ) Equation 6
[0048] It is also recognized that, for embodiments five and six, pressures Pc and Ps can be supplied by another means that can be at a pressure as low as vacuum. It can be any pressure source below Ph, or even sealed with some fixed pressure that is less than Ph. The pressure that is selected needs to be high enough so that the spring 8 which is needed to have the valve disc seal when it is off does not impose excessive force when the refrigerator is operating.
[0049] FIG. 11 shows the seventh embodiment in which the construction of valve assembly 29 is very similar to that of FIG. 7 however the gas flow through the valve disc is in the reverse direction. High-pressure gas line 19 is connected to port 10 on valve assembly 29 and low-pressure gas returns to compressor 20 through port 14 and line 18 . This results in the conventional flow of gas through valve disc 34 with high-pressure gas on the outside. With valve disc 34 pinned by 3 to motor shaft 6 the axial load is carried by the motor bearings in the direction toward the valve face. FIG. 11 shows the shoulder area As in 31 being pressurized at Ph, and the surface area Ac in 39 being pressurized by Pl. In a conventional valve assembly the rotary valve disc is not pinned and the axial force is the product Av*(Ph−Pv avg.). The torque required to turn the valve disc can be reduced relative to conventional single piece valve discs by having two different pressures acting on two different surfaces in valve seat 31 . In order to reduce the force of valve disc 34 against seat 33 but still have it seal the following relationship must be observed,
0<( Ac*Pl+As*Ph−Asa*Ph )< Av* ( Ph−Pv max) Equation 7
[0050] The eighth embodiment of this invention as shown in FIG. 12 is similar to the previous embodiment. Like reference numerals denote like parts in FIG. 11 . The difference between this embodiment and embodiment seven is that the pressures in shoulder region 31 is Pl and the pressure in center cavity 39 is Ph. The relationship that must be observed in order to reduce the force of valve disc 34 against seat 33 , but still have it seal, is similar to equation 7,
0<( Ac*Ph+As*Pl−Asa*Ph )< Av* ( Ph−Pv max) Equation 8
[0051] It is obvious that for embodiments three to eight which have two different pressures acting on two different surfaces in the valve seat, that one or more additional shoulders can be added that are sealed from each other and are independently pressurized from other sources. It would seem to be impractical but not impossible to add additional surfaces at different pressures to the valve discs in embodiments one and two.
[0052] The ninth embodiment of this invention is shown in FIG. 13 , where like reference numerals denote like parts in FIG. 10 . This is a special case of embodiment six, FIG. 10 , that arises when the criteria of equation 6 is met with As=0. A practical design is to use the buffer gas, as shown in FIG. 13 , to pressurize Ac in cavity 39 . Other pressures from other sources can also be used.
[0053] The tenth embodiment of this invention is shown in FIG. 14 , where like reference numerals denote like parts in FIG. 12 . This is a special case of embodiment eight, FIG. 12 , that arises when the criteria of equation 8 is met with As=0 and the pressure in cavity 39 at a pressure less than Ph. Buffer gas may be used, as shown in FIG. 14 , to pressurize Ac in cavity 39 . Other pressures from other sources can also be used.
[0054] The seventh, eighth, and tenth embodiments shown in FIGS. 11, 12 , and 14 , all have high pressure gas on the outside of the valve disc and low pressure in the center of the valve disc face. They are not as attractive as the embodiments with high pressure in the center of the valve disc face because wear dust from valve disc 34 tends to blow into the pulse tube or other expander. It does however provide a means of reducing the motor torque, which is particularly important in valves that have more ports than those shown in FIGS. 2, 3 , 5 , and 6 . | A rotary valve unit which reduces the torque required to turn the valve disc, and the amount of wear dust that is blown into the cold head, using differential gas forces to keep the valve disc in contact with the valve seat, and which enables larger diameter valve discs to be utilized for multi-ported pulse tubes that have less force on the face of the valve disc, resulting in reduced torque and reduced wear rate. | 5 |
This application is a continuation of Application Ser. No. 431,111, filed on Nov. 3, 1989.
BACKGROUND OF THE INVENTION
1. Field of Application
The present invention is related to the building industry and deals particularly with an improved system for the enlargement of pre-existant buildings, in a gradual, simple and inexpensive way.
Such a system has been a long sought objective for low income families whose savings need be immediately used and maximized.
This system would prove to be not only desirable but necessary in countries with high demographic growth and a low income per capita.
Recently in Mexico and other contries the housing problem was worsened alarmingly due to such factors as population growth, lack of financial resources, scarce specialized labour and the rising cost of building materials.
In the case of Mexico, it is estimated that during the next ten years more than 8,000,000 low income families with hardly any access to credit will be in need of a dwelling. Therefore, the building of these dwellings will depend on the small amounts of capital saved by each family through a long period of time.
Thus, a great mass of effective demand will be characterized as an atomized demand. one which needs and can purchase small portions of a dwelling. To prove this point we only need to walk through any squatter settlement and see a multitude of construction signs pointing to the future development of the dwellings, specially obvious are: piles of building material, foundations without walls, walls without slabs, temporary constructions and the everpresent steelbars protruding from concrete elements.
In Mexico the public sector finances aproximatly 30% of the dwellings for low income families, while the informal or social sector is responsable for the other 70%.
The investment currently undergone by the public sector in projects concerning sites and services, progressive construction, and improved housing justifies the participation of large enterprises. Nevertheless, due to a lack of appreciation of the informal market and the traditional inertia in the building industry we find that products now on the marketplace do not address the problems and possibilities posed by the gradual growth of construction.
Likewise in the informal sector, the size and singularity of each atom of demand inhibits the intervention of specialists and the efficient solution of design and construction problems. In a similar way the owner generally depends on low qualified labour including his own, this results in a large waste of resources and poor quality construction.
2. Description of the Previous Technique
Recent studies in Mexico indicate that 80% of the dwellings built use one variation of the so called traditional system characterized by load bearing walls made with a variety of brick types, the walls are reinforced with horizontal and vertical elements of reinforced concrete, and floor slabs and roofing generally made of reinforced concrete.
Whatever applies for the traditional system is also valid for any future extension of the building. As a result the building of an extension usually follows the next sequence: first, foundations are built, then the brickwork conforming the walls is laid and the vertical concrete reinforcements poured, next the steel bars of the horizontal wall reinforcements are placed and the concrete slab is built. In some instances before the slab is built temporary roofing is installed which is substituted for the slab in a later stage. The same procedure will be followed for extensions in upper levels obviously skipping the foundations.
In this manner, with the traditional system the brickwork will remain unstable until the vertical reinforcements are poured, and the reinforcements can not be poured until all the concurrent walls are built. This implies that all foundations, brickwork and vertical wall reinforcements must be built in order to atain a load bearing and stable structure.
When building with the previous technique, qualified personnel are required to establish the right spatial references so that the construction fulfils a pre-established geometry. For this reason poorly qualified or unskilled labour like the owner himself must always work under the supervision of qualified personnel.
The building technique previously described presents a series of problems that are of the greatest importance when dealing with the gradual extension of a building, since it can not effectively use the small capital flows that feed the construction of the dwelling in a gradual way.
One of the main disadvantages of the extensions built with the previous technique comes from a large underemployed capacity, which is fully used years later when the building is finally completed.
Another disadvantage of the previous technique results from the order of execution, because the vertical wall reinforcements are poured after the brickwork is laid they can not be used to support the guiding string which allows for the correct placement of each brick, furthermore, the brickwork will remain unstable until the vertical reinforcements are poured.
Given the above, all the brickwork and the vertical reinforcements must be concluded in a relatively short period of time with the permanent presence of qualified workmen. Furthermore, due to the temporary instability of the brickwork there is a real danger to workmen and to personnel in the surrounding areas.
Although the improved system of progressive construction has been focusing specifically on the extension of dwellings it is obvious that this type of construction may be used for any other purpose.
SUMMARY OF THE INVENTION
The principal objective of this invention is to present an improved building system that focuses on the gradual growth of construction with an immediate use of each unit invested.
Another objective of this invention is to present a pre-cast vertical wall reinforcement, to be used not only on said system but also on any other type of construction wherever brickwork is used to form load bearing or partition walls or wherever light structures or temporary roofings are required.
One advantage of the present invention is that a minimum investment enables the placing of a light roof which is immediately useful, while using the previous technique this same initial investment would only provide enough resources to excavate and build part of the foundations.
Another advantage of the system of this invention is that it will allow for a multiple reutilization of the temporary roofing.
The separation of qualified and unqualified labour is another advantage of the present invention. Marking the geometry of the extension with the initial vertical wall reinforcements allows for unqualified labour to continue building without the assistance of qualified personel. This is very advantageous considering that the owner generally applies his spare time to building.
Another advantage of the system of this invention is that the dwelling may grow by small increments immediately incorporating family savings into a useful project. Generally such savings will be applied to purchase building material which only after many years will it be of any use, and before this happens the investment will generate a so called negative utility, since material placed in the exterior
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the first stage of an extension built with the system of the present invention. It is compared with FIG. 2.
FIG. 2 is a view of a perspective showing what could be built using the previous technique and an investment equal to the one used to build the extension shown in FIG. 1.
FIG. 3 is a front view of a construction and shows the first stage of an extension in an upper floor.
FIG. 4 is a front view of the construction shown in FIG. 3 illustrating the second stage of the same extension.
FIG. 5 is a front view of the construction shown in FIGS. 3 and 4 illustrating the placement of a permanent roofing and the termination of the extension in the upper floor. It also shows the initial stage of an extension on the ground floor.
FIG. 6 is a perspective view showing the termination of the initial stage in the construction of an extension at ground level.
FIG. 7 is a perspective view showing the side by side development of foundations, complementary vertical wall reinforcements and brickwork.
FIG. 8 is a perspective view of the structure that supports the temporary roofing.
FIG. 9 is an isometric view showing the connection principle between 4 walls and a vertical wall reinforcement.
FIG. 10 is a longitudinal section showing the reinforced connection between the brickwork and the precast vertical wall reinforcement.
FIG. 11A is a transverse section of a precast vertical wall reinforcement with trapezoid indentations.
FIG. 11B is a partially cut away view of a precast vertical wall reinforcement showing various shapes of indentation cross sections.
FIG. 12 is an isometric view showing the mounting of a precast vertical wall reinforcement supported by the connections formwork.
FIG. 13 is a front view showing the mounting of a precast vertical wall reinforcement supported by a steel bar.
FIG. 14 is an isometric view showing the steel bar arrangement of the connection of a precast vertical wall reinforcement installed on a surface.
FIG. 15 is an isometric view showing a finished connection which has the same section as the precast vertical wall reinforcement.
FIG. 16 is a longitudinal section showing an extended connection of a precast vertical wall reinforcement.
FIG. 17 is an isometric view illustrating how the extended connection illustrated in FIG. 16 becomes part of the brickwork in a later stage.
FIG. 18 is a longitudinal section showing the connection between a precast vertical wall reinforcement and the foundations.
FIG. 19 is an isometric view showing an arrangement of a steel reinforcement for a horizontal reinforced concrete element provided to a previously installed precast vertical wall reinforcement.
FIG. 20 is an isometric view showing the connection between a precast vertical wall reinforcement and a block poured at the site.
FIG. 21 is a longitudinal section showing the connection between a precast vertical wall reinforcement inside a block previously formed.
FIG. 22 is a longitudinal section showing how to arrange steel bars to form a horizontal connection resistant to bending and extraction.
FIG. 23 is a longitudinal section showing the connection between a precast vertical wall reinforcement and a horizontal reinforced concrete element.
FIG. 24 is a longitudinal section showing how a wood beam is joined to the upper part of a precast vertical wall reinforcement.
FIG. 25 is an isometric view of the connection shown in FIG. 24.
FIG. 26 is an isometric view showing the connection between a reinforced concrete wall and a precast vertical wall reinforcement.
FIG. 27 is an isometric view showing the placement of wood blocks in the indentations of a precast vertical wall reinforcement and the filling of these.
FIG. 28 is an isometric view showing one method of connecting a wood beam to an indentation of a precast vertical wall reinforcement.
FIG. 29 is an isometric view showing one method of connecting a steel beam and a tightener to the indentations of a precast vertical wall reinforcement.
FIG. 30 is an isometric view showing the installation of a concrete bracket using one of the indentations of a precast vertical wall reinforcement.
FIG. 31 is an isometric view showing one possible installation of hand rails using the indentation of a precast vertical wall reinforcement.
DETAILED DESCRIPTION OF THE INVENTION
The improved building system for the progressive extension of dwellings consists of a series of stages and components to be described in full as follows:
FIGS. 1 and 2 are a comparison of what can be accomplished with a given investment during a first stage of construction using the system of the present invention as shown by FIG. 1, and what could be achieved with the same amount invested and the traditional system, as shown by FIG. 2. As can be seen, given a previous construction 1, and a minimum investment, the system of the present invention would produce a light and reusable roofing 2 providing immediate benefits to the user, while using the previous technique would only produce the foundations, the owner then would have to wait several years in order to accumulate enough savings to complete the extension and obtain some benefit from the investment.
FIG. 3 illustrates the first stage of construction of an extension in an upper level of a previously built dwelling.
The extension will be built over a previously built portion 1, which preferently will have precast vertical wall reinforcements 4' where a connection of a future wall is expected. The initial precast vertical wall reinforcements 4 will be placed in the first stage, but only in the number required to support the structure of the temporary roofing 2 and the elements 5 which comprise it.
As shown in FIG. 4, in the second stage of construction, one may proceed to entirely enclose the space, by installing complementary precast vertical wall reinforcements 6 or by pouring these elements at the site as is conventionally done. Load bearing brickwork 7 would also be laid, the required windows and doors 8 would be installed and the wedges formed by the sloping roof 2 would be covered with roofing sheets 9.
In FIG. 5 the next stage of construction shows a properly finished extension with a slab 10. Here the final elements of the temporary roofing are removed to be installed in a new extension, that is the roofing 2 and the elements 5 forming its structure which will be described in detail later on. Once this is done one would proceed to build the final concrete slab 10 and finally the finishings and the internal partitions if so required.
The stages previously described are only one of the many possible alternatives of this system.
As a second prefered alternative in the second stage of construction the owner may enclose the space with provisional walls made from sheets and the walls so built could deteriorates and obstructs part of the site, while if placed undercover it will hinder and crowd the house, occupying scarce and valuable covered space.
The system of the present invention allows for the building of extensions without obstructing or interfering with former constructions and since the later portion of the extension can be built undercover the workers productivity will increase and the halting of work due to rain will be diminished.
Another advantage of the present invention is that extensions may consolidate through very small increments including the gradual construction of foundations. This will enable the installation of temporary walls instead of final ones, portion by portion, or side by side without dismounting the temporary roof.
One more advantage of the system of this invention is that it allows for a very gradual growth the construction and can be easily modified according to the needs and preferences of the owner without involving costly adaptations. The possibility of growth by small increments also provides diversity and individuality to the dwelling, since even if the same prototype is used each unit will distinguish itself according to its particular degree of development.
Another advantage of the present invention results from the way brickwork is joined to the vertical wall reinforcements. This joint as will be seen later on does not require the simultaneous construction of all the brickwork that concurrs to a given vertical reinforcement. Hence, load bearing walls can be built before non bearing walls are erected, and construction can follow a room by room sequence instead of a floor by floor procedure.
Yet another advantage is that the vertical reinforcements can be poured at the factory using a single mould and later, at the site, each unit can be adapted to serve under different circumstances as would be different heights, different lateral, top and bottom connections to a variety of structural and constructive elements such as: walls, beams, joists, doors and windows.
Another advantage results from placing the vertical reinforcements before the brickwork is laid. With this procedure each layer of brick is connected and secured to the vertical reinforcement, avoiding the danger posed by the temporary instability of the brickwork, furthermore, when construction is done above ground level the vertical reinforcements can be used to support temporary protective hand rails.
These as well as other objectives and advantages of the present invention are at least partly understood and others will become clear following review of the description and the illustrations of the invention. In a later stage be substituted one by one with final load bearing walls.
To illustrate this type of growth FIGS. 6 and 7 show the construction of an extension on a ground floor.
The system is basically the same as the one previously described, its objective being that of consolidating a re-usable roof in the first stage of construction as shown in FIG. 6. This will require partial foundations 3 to support the initial precast vertical wall reinforcements 4 to be placed according to a pre-established geometry of the extension, and which will support a wood or steel dismountable structure 5 to which the roof 2 is attatched.
FIG. 7 shows a second stage in which the foundations 3, the horizontal reinforcement 11, the brickwork 7, and the complementary vertical wall reinforcement 6 of a single side of the extension are built.
In this manner and following the system of the present invention the construction can follow a multidirectional order minimizing idle investment, since, from the very beginning, foundations and vertical wall reinforcements are partially built and a temporary roofing is installed. As time goes by the building will be completed with the speed and direction that correspond to the income and preferences of the owner.
FIG. 8 shows the structure which supports the temporary roofing. It consists of a main girder 12 resting upon precast vertical wall reinforcements 4. Parallel to the main girder in the back side of the extension and at a higher point, another secondary girder 13 bears on a pair of receptors 14 which are firmly connected to the previous construction 1. Following this and resting on both girders are a series of rafters 15 supporting a series of minor beams 16, which in turn receive the load from the elements forming the roof. It is worth noting that when using structural roofing elements of large span, rafters and minor beams can be spared.
As mentioned before one of the constituents of the system are the precast vertical wall reinforcements that support the structure of the temporary roofing and that differ from those of the traditional system in that they are installed before the brickwork is laid. This change of order allows for the in-factory pouring of the reinforcements that will later be installed at the building site.
The precast vertical wall reinforcements are concrete elements reinforced with four longitudinal steel bars 17 and transverse steel 18 as shown by FIGS. 9-31. As a distinguishing feature, a series of adjacent indentations of considerable depth are arranged on each of the four sides of the element. As will be described later, this arrangement together with the mobility of the precast element allows for its easy adaptation to diverse conditions, and the accomplishment of multiple functions not necessarily related to the conventional progressive construction of dwellings.
The connection principle between a segment of a precast vertical wall reinforcement 4 and four concurrent walls 7 is shown in FIG. 9. Here the indentation 19 of the precast vertical wall reinforcements are filled with mortar keys 20 that protrude from the wall. This arrangement forms a connection resistant to shear in the plane of the wall and in a perpendicular direction to it. This connection can be reinforced by interconnecting bent steel reinforcements or reinforcing members such as bars 22 in the horizontal mortar joints of the brickwork 21 as shown in FIG. 10.
In a transverse section the indentations of the precast vertical wall reinforcement can be trapezoidal in shape as shown in FIG. 11 semicircular or rectangular, but always allowing easy access by a masons pointing trowel 23 as shown by dot-dash line in FIG. 11. The indentations limit a core 24 free from steel since they are placed along the rectangles formed by the longitudinal 17 and transverse 18 bars. As may be observed the depth of the cells 19 can exceed the planes defined by the steel reinforcement without reducing the appropiate covering of the bars.
FIG. 11B shows a precast vertical wall reinforcement 4 of rectangular cross-section. Two planar outer surfaces with indentations having cross section shapes that are trapezoidal (19a), triangular (19b), rectangular (19c) and semi-circular (19d), are shown. Two rear planar surfaces not visible in this figure may have similar indentations therein.
As will be described later, the indentations: provide the means to connect the brickwork, and reduce the weight of the element and enable its adaptation to different circumstances. This multifunctional characteristic justifies the use of only one mold in the production of all the precast vertical wall reinforcements placing indentations along their length and on their four sides. Thus, at the building site, each indentation can be easily activated or cancelled according to specific requirements.
In order to connect the precast vertical wall reinforcement to the structure, its longitudinal steel bars can project beyond the concrete in its upper and lower portion, and to facilitate mounting operations each element can have a piece of steel pipe in the lower portion of the concrete.
At the building site the mobility of the precast vertical wall reinforcement facilitates the preparations done on it since it can be stored in an area with electricity and worked in a horizontal position.
Once the precast vertical wall reinforcement has been adapted to perform its specific functions it can be easily moved by two workmen to the place where it will be mounted. There, it may be placed horizontally and two of its four sides will be fixed to the formwork 25 that forms the connection shown in FIG. 12. Another mounting alternative uses the mounting steel pipe 27 to insert a steel bar 26 as shown in FIG. 13. Later it will be erected with a rotating motion until it reaches the vertical position. Once in the vertical position the element will be laterally supported and properly plumbed, the transverse steel 28 of a connection will be placed around the projecting longitudinal bars 29 of the element 4 and those anchored at the site 30, as shown in FIG. 14. Finally the formwork of the connection will be completed and the concrete poured.
This method of installation is advantageous since it does not require special mounting equipment and the height of the precast element can be controlled with the formwork or with the length of the steel bar inserted into the mounting pipe.
FIG. 15 shows a finished connection 31 with the same section as the precast vertical wall reinforcement. In this case the concrete of the connection 31 would be poured in two stages. In the first one the larger part of the connection would be poured through a window set on one side of the formwork. Following this, the window would be closed and one of the four bottom cells would be used to complete the pouring while the other three could be used to verify the filling of the connection.
FIG. 16 shows an extended connection. This alternative uses the extended part 32 to facilitate the pouring of the connection, and later, the extended part can form part of the brickwork on one of its sides, as shown in FIG. 17.
FIG. 18 shows a direct connection between a precast vertical wall reinforcement 4 and the foundations 3. In this case as usual, the foundations form the formwork of the connection. This type of connection is specially important to progresively built constructions since a minimum investment enables the instalation of the precast vertical wall reinforcements and a temporary roofing even before the horizontal reinforcement of the foundation is built, which in this case can be poured at a later stage by placing longitudinal bars 33 on each side of the precast vertical wall reinforcement as shown in FIG. 19.
FIG. 20 shows another possible connection of the precast vertical wall reinforcement. Here the precast element bears directly on a surface and a reinforced and anchored concrete block 34 is later poured. In this case the indentations immersed within the concrete block forms a connection resistant to pulling and bending actions.
FIG. 21 shows how a precast vertical wall reinforcement can be connected to a previously formed block 35. In this case the block is filled with concrete and the precast element is placed supported on the border with its steel bars 29 firmly anchored within the block.
As has been previously mentioned, the deep indentation on the sides of the precast element allow for its adaptation to different circumstances. One such adaptation is shown in FIG. 22 which illustrates the preparation to join a precast vertical wall reinforcement to a horizontal reinforced concrete element like a lintel or a window sill. As can be seen, with the use of a conventional drill holes 36 are perforated through the core 24 of the precast element 4 at a preestablished indentation. This is easily performed since the depth of the indentations considerably reduces the depth of the core. Next, two steel bars 37 bent at 90 are introduced through the holes and concrete is poured in the upper indentations 19 completely covering and anchoring the steel bars 37. This preparation can be easily accomplished with the precast element being in a horizontal position. Once the preparation has hardened, the precast element can be installed and later joined to the horizontal element 38 as shown by FIG. 23.
FIG. 24 shows how a wood beam 39 can be connected to the upper part of a precast vertical wall reinforcement. In this case the connection is accomplished by drilling a hole in the upper part of the upper indentation in a perpendicular direction to the beam. Next, using a bolt 40, wood laterals 41 and fillings 42 are joined to both sides of the precast element. Finally the top fillings and the beam are attached to the laterals by way of a second through bolt. With this connection the precast element retains its upper steel prolongations 29 as shown in FIG. 25. Thus whenever it is required the beam and the connection can be disassembled and the precast element's upper part can be joined to a final construction.
FIG. 26 shows the connecting method between a precast vertical wall reinforcement and a reinforced concrete wall 43. Here the precast element is prepared by drilling a series of holes through its core. The holes are then used to pass through the horizontal steel reinforcement 44 of the wall. In this case the precast element can also be used to separate and align the formwork 45 for the wall 43. In case the wall ends at the precast element, a preparation like the one shown in FIG. 22 can be provided on several of the indentations.
When the indentation in the precast element present an inconvenience or are simply not used they can be easily eliminated by filling them with a concrete or mortar mix 46 as shown by FIG. 27. This can be easily done when the precast element is in a horizontal position. The cells can also be used to place wooden blocks 47 to which doors windows and other accesories can be easily fixed. Still other inlays can be installed for the purpose of enhancing the appearance of the precast element.
As can be seen the mobility of the precast element and the ease with which its core can be drilled combined with the possibility of filling its indentation enables the still other multiple connections like the ones shown in FIGS. 28 through 31.
In FIG. 28 a wooden beam 39 is connected to an indentation using steel connectors 48 fixed to the precast element's core with through bolts or screws. The corresponding indentations are then filled with concrete or mortar 46. FIG. 29 shows a similar connection, only here a steel joist 49 is joined to the precast element together with a tightener 50 which can provide for lateral bracing.
FIG. 30 shows a concrete bracket 51 attached to the precast element, this can be easily done using the preparation of FIG. 22. Finally FIG. 31 shows provisional wood hand rails 52 fixed to the precast element by way of through bolts across its core. These elements could be used to provide protection for the workmen. | A building method and system for the progressive construction of extensions in a dwelling, where the layout of the extension has been previously established. The system is composed of three stages. In the first stage, only the necessary foundations are built, a limited number of precast vertical wall reinforcements and a temporay roofing are installed. In the second stage, load bearing walls are erected and fixed to the initial vertical wall reinforcements with mortar keys that fill indentations in the precast elements, complimentary wall reinforcements are poured and lintels, doors and windows are installed. In the third stage, the temporary roofing is relocated at a second extension while in the first extension a permanent slab is built and the interior partitions and finishes are installed. The vertical wall reinforcements are cast concrete members of rectangular cross section, have internal longitudinal and transverse reinforcing bars, and are formed with a plurality of indentations of trapezoidal, rectangular, semi-circular or triangular cross section shape cast in the outer surface. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Application Nos. 60/147,375, filed Aug. 4, 1999, No. 60/147,513, filed Aug. 5, 1999, and No. 60/147,514, filed Aug. 5, 1999.
ORIGIN OF INVENTION
The invention described herein was made in the performance of work under a NASA contract, and is subject to the provisions of Public Law 96-517 (35 U.S.C. §202) in which the Contractor has elected to retain title.
1. Technical Field
This invention relates to imaging systems, and more particularly to Quantum Well Infrared Photodetectors.
2. Background
Infrared imaging is widely used in a variety of applications including night vision, surveillance, search and rescue, remote sensing, and preventive maintenance, to name a few. Imaging devices to provide these applications are typically constructed of HgCdTe or InSb focal plane arrays. These focal plane arrays are known to be pixel mapped devices, where an array element is generally mapped to one or more circuit elements. However, such focal plane arrays are difficult to manufacture and expensive. Quantum Well Infrared Photodetectors (QWIPs) can detect mid and far infrared light, providing an output current as a result.
GaAs based Quantum Well Infrared Photodetectors are useful for several applications such as target recognition and discrimination which require mid-wavelength:long-wavelength, long-wavelength:long-wavelength, and long-wavelength:very-long wavelength large area, uniform, reproducible, low cost and stable multi-color infrared focal plane arrays (FPAs). For example, a two-color FPA camera would provide the absolute temperature of a target which is extremely important to the process of identifying temperature difference between targets, war heads and decoys. On the other-hand, two-color is not sufficient in identifying the absolute temperature of objects in the presence of a third variable such as the Earth's reflection in exo-atmospheric applications. Thus, three-color FPAs are more suitable for exo-atmospheric target recognition applications.
Random reflectors are potentially broadband optical coupling structures for QWIPs. When combined with a thinned QWIP substrate, the random surface can trap the optical field by reflecting the waves at different angles on each bounce. For efficient coupling to the absorbing QW layer, the surface should (1) diffract efficiently into high angles, and (2) have near-zero diffraction efficiency at low angles. Condition 1 can be produced by a surface that has significant depth variation on the scale of one wavelength. Condition 2 can be produced by a surface that produces destructive interference of all reflected waves in the direction normal to the surface. To produce a broadband optical coupling structure, both conditions need to be satisfied over a significant wavelength range. Zeroing the normal reflection, however, is the more important condition since any normally reflected light is lost without any absorption. The structures described here can produce a minimal normal reflection over a significant wavelength range. In all the simulations, scalar electromagnetic theory is used, and this is only an approximation when the wavelength is on the order of the feature size.
Imaging systems that operate in the very long wavelength infrared (VLWIR) region are required in a variety of NASA's earth science applications, such as geological and volconological studies, monitoring global atmospheric temperature profiles, cloud characteristics, and relative humidity profiles. This is mainly due to the fact that most absorption lines of atmospheric gas molecules such as ozone, water, carbon dioxide, carbon monoxide, sulfur dioxide, and nitrous oxide occur in the LWIR spectral range. In addition, 12-18 μm focal plane arrays (FPAs) would be very useful in detecting cold objects such as ballistic missiles in midcourse (when hot rocket engine is not burning most of the emission peaks are in the 8-15 μm IR region). Thus, it is desirable to develop highly sensitive, low power dissipation, large, VLWIR FPAs which can simplify the design and construction of infrared imaging systems.
Spectral response of conventional interband infrared (IR) detectors are completely determined by the bandgap because photoexcitation occurs across the band gap (E g ) from the valence to conduction band. Therefore, detection of very is long wavelength IR radiation requires small bandgap materials such as Hgl −x Cd x Te and Pbl −x Sn x Te, in which the energy gap can be controlled by varying x. It is well known that these low band gap materials are more difficult to grow and process than large band gap semiconductors such as GaAs. Although, these detectors in single element format show high performances at higher operating temperatures, it is extremely difficult to produce them in large format uniform arrays.
Quantum Well Infrared Photodetectors avoid such difficulties because they are fabricated using high bandgap materials systems such as GaAs/Al x Ga 1−x As. The detection mechanism of QWIP involves photoexcitation of electrons between ground and first excited states (subbands) of the quantum well which is created in the conduction band due to bandgap difference in the material system. Quantum well parameters for GaAs/Al x Ga 1−x As material systems can be designed to detect light at any wavelength from 6 to 25 μm range. The advantages of QWIPs compared with HgCdTe detectors include high uniformity, excellent reproducibility, low 1/f noise and low-cost large-area staring arrays. However, it is difficult to obtain this signal to noise ratio for VLWIR QWIPs at high operating temperatures. This is due to high dark current which is dominated by classical thermionic emission at such operating temperatures.
SUMMARY
The present invention includes a three-color QWIP focal plane array. The three-color QWIP focal plane array is based on a GaAs/AlGaAs material system. Three-color QWIPs enable target recognition and discriminating systems to precisely obtain the temperature of two objects in the presence of a third unknown parameter. The QWIPs are designed to reduce the normal reflection over a significant wavelength range.
One aspect of the present invention involves two photon absorptions per transition in a double quantum well structure which is different from typical QWIP structures. This design is expected to significantly reduce the dark current as a result of higher thermionic barriers and therefore allow the devices to operate at elevated temperatures. The device is expected to be fabricated using a GaAs/Al x Ga 1−x As material system on a semi-insulating GaAs substrate by Molecular Beam Epitacy (MBE).
DESCRIPTION OF DRAWINGS
These and other features and advantages of the invention will become more apparent upon reading the following detailed description and upon reference to the accompanying drawings.
FIG. 1 shows a schematic conduction band diagram of the bound-to-continuum, bound-to-quasibound, and bound-to-bound three color QWIP according to one embodiment of the present invention.
FIG. 2 is a three dimensional view of the three color QWIP device according to an embodiment of the present invention.
FIG. 3 is a side view of the three color QWIP device of FIG. 2 according to an embodiment of the present invention.
FIG. 4 illustrates the responsivity spectrums of the three color QWIP device according to an embodiment of the present invention.
FIG. 5 illustrates an achromatic random reflector depth, reflectivity as a function of wavelength, and angular spectrum of reflected waves according to one embodiment of the invention.
FIG. 6 illustrates a minimum achromatic random reflector depth, reflectivity as a function of wavelength, and angular spectrum of reflected waves according to one embodiment of the invention.
FIG. 7 illustrates a monochromatic achromatic random reflector depth, reflectivity as a function of wavelength, and angular spectrum of reflected waves according to one embodiment of the invention.
FIG. 8 illustrates a minimum depth monochromatic random reflector depth, reflectivity as a function of wavelength, and angular spectrum of reflected waves according to one embodiment of the invention.
FIG. 9 is a schematic conduction band diagram of a portion of the photon assisted quantum well IR detector under bias.
FIG. 10 is a schematic band diagram of a single quantum well according to an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 shows the schematic conduction band diagram of the proposed three-color QWIP device which utilizes bound-to-continuum (B-C) 105 , bound-to-quasibound (B-QB) 110 , and bound-to-bound (B-B) 115 intersubband absorption. The device structure consists of a stack of 30 periods of a 7-8 micron bound-to-continuum photosensitive multi-quantum well (MQW) structure, a stack of 30 periods of a 10.5-11.5 micron bound-to-quasibound photosensitive MQW structure, and another stack of 30 periods of a 14-15 micron bound-to-bound photosensitive MQW structure. All three photosensitive MQW stacks will consist of 30 periods of 500 Å Al x Ga 1−x As barrier and a GaAs well. These three stacks are separated by two 0.5 micron thick doped GaAs contact layers 120 .
The Al mole fraction x and GaAs quantum well width of each MQW stack are tuned independently to obtained the desired infrared detection wavelength and the most suitable device structure. (i.e., B-C, B-B, or B-QB). This entire three-color QWIP structure is then sandwiched between 0.5 micron GaAs, top and bottom contact layers doped n=5×10 17 cm −3 , and will be grown on a semi-insulating GaAs substrate by molecular beam epitaxy (MBE). Then a 1.3 micron thick GaAs cap layer on top of a 300 Å Al 0.3 Ga 0.7 A stop-etch layer will be grown in situ on top of the device structure to fabricate the light coupling optical cavity.
FIG. 2 shows a schematic diagram of a three-color QWIP pixel 200 . The present invention allows independent access to all three vertically integrated QWIPs 205 , 210 , and 215 . QWIPs 205 , 210 , and 215 do not absorb radiation incident normal to the surface since the light polarization must have an electric field component normal to the layers of superlattice (growth direction) to be absorbed by the confined carriers. As a consequence, for imaging, it is necessary to be able to couple light uniformly to two dimensional arrays of these detectors. The infrared radiation can be coupled to the detectors in the FPA by fabricating randomly roughened reflecting surfaces or two dimensional cross gratings. The photoexcitation of the confined carriers in the MQW region occurs due to non zero polarization components of the reflected light along the growth direction.
After the achromatic random reflector is defined by the lithography and dry etching, the photoconductive 7-8 micron QWIPs are fabricated by dry etching through the first stack of photosensitive GaAs/Al x Ga 1−x As MQW layers 220 into the 0.5 μm thick first heavily doped GaAs intermediate contact layer 225 . Then the photoconductive 10.5-11.5 micron QWIPs will be fabricated by dry etching through the second stack of photosensitive GaAs/Al x Ga 1−x As MQW layers into the second heavily doped GaAs intermediate contact layer 225 . Then the photoconductive QWIPs of the 14-15 micron QWIPs will be fabricated by dry etching through the third stack of photosensitive GaAs/Al x Ga 1−x As MQW layers into the 1.0 μm thick heavily doped GaAs bottom contact layer. The achromatic random reflectors on top of the detectors will then be covered with Au/Ge and Au for Ohmic contact and reflection.
FIG. 3 shows a side view 300 of the QWIP device. Separate metal contact layers 335 are fabricated on 8-9, 10.5-11.5 and 14-15 micron QWIPs during the metalization process. Therefore, the fill factor of the top 14-15, middle 10.5-11.5, and bottom 8-9 micron detectors will be about 80%, 85%, and 90% respectively. Then indium bumps 230 can be evaporated onto all four metal pads of each QWIP pixel to achieve independent access to all three vertically integrated three-color QWIPs. The advantages of this approach include simultaneous readout and full spatial resolution for all three wavelength bands. FIG. 4 shows the responsivity spectrums 400 of all three wavelength bands of the proposed three-color QWIP.
Proposed three-color QWIP device structures may be grown on three-inch semi-insulating GaAs substrates 340 by using MBE. During the materials growth process the materials quality will be optimized against many growth parameters such as substrate temperature and growth rate. These materials are tested prior to test device fabrication using Hall measurements, photoluminescence, and X-ray diffraction.
For ease of lithographic fabrication, the surface will be composed of square pixels having variable depth. Assuming normal incidence and equal reflectivity of all pixels, the condition for null reflection at zero angle is ∑ p exp [ φ p ( λ ) ] = 0 ( 1 )
where p is the pixel index, φ p =4πd p /λ is the phase delay of pixel p, d p is the depth of pixel p, and λ is the wavelength inside the material. If the random surface is made up cells having 2×2 pixels, there are a variety of ways one can choose the pixel depths for minimum reflection. In all the designs, the goal is to design around a free space wavelength of 15 μm, the refractive index is 3.1, and the pixel size is 2.5 μm.
Equation (1) can be satisfied at two wavelengths if the depths are chosen as:
d 1 =rand (0 . . . λ 1 /4),
d 2 =d 1 +λ 1 /4,
d 3 =d 1 +λ 2 /4,
d 4 =d 1 +λ 1 /4+λ 2 /4
Pixel 1 is given a random depth and the locations of d 1 . . . d 4 within the cell are selected at random to make the overall surface highly random. When the pixels have these depths, they produce destructive interference in pairs. At λ 1 , destructive interference occurs between pixels 1 and 2 , and between pixels 3 and 4 . At λ 2 , destructive interference occurs between pixels 1 and 3 , and between pixels 2 and 4 .
FIG. 5 shows a gray-scale representation of a surface composed of such cells 500 , the reflectivity as a function of wavelength 505 , and the angular spectrum of reflected waves 510 . The angular spectrum 510 is a gray-scale representation of the diffraction efficiency as a function of angle in two dimensions (the angle of incidence is zero). All waves inside the circle of radius sin (θ)=1 are propagating, and those outside the circle are evanescent. The reflectivity goes to zero at the two design wavelengths and the diffraction efficiency at high angles is strong-this is critical for QWIP absorption. Since this structure has zero reflectivity at more than one wavelength, it can be called “achromatic”. The broadband nature of this structure also increases the etch depth tolerance during fabrication.
The structure in FIG. 5 can only be fabricated by analog-depth lithography (E-beam) due to the random depth of pixel 1 . If the depth randomness is removed, i.e.
d 1 =0,
d 2 =λ 1 /4,
d 3 =λ 2 /4,
d 4 =λ 1 /4+λ 2 /4.
then the resulting structure still has null reflectivity at two wavelengths, but it is shallower and could be fabricated using a two-step photolithography and reactive-ion etch process. This structure is shown in FIG. 6 . The first etch would be λ 1 /4 and the second etch would be λ 2 /4. FIG. 6 shows a gray-scale representation of a surface composed of such cells 600 , the reflectivity as a function of wavelength 605 , and the angular spectrum of reflected waves 610 . These characteristics of this reflector are nearly as good as the analog-depth version.
A single-wavelength design is
d 1 =rand (0 . . . λ 1 /4),
d 2 =d 1 +λ 1 /4,
d 3 =rand (0 . . . λ 1 /4),
d 4 =d 3 +λ 1 /4
FIG. 7 shows that the resulting structure looks as random as the achromatic structure of FIG. 5, but the reflectivity 705 is zero at only a single wavelength. This puts a tight tolerance on the etch depth during fabrication.
A minimum-depth single-wavelength design is
d 1 =0,
d 2 =λ 1 /4,
d 3 =0,
d 4 =λ 1 /4
FIG. 8 shows that the resulting structure is only random in the position of the pixels, and the reflectivity is much worse than the structures from FIGS. 5-8.
The schematic band diagram 900 of the present invention is shown in FIG. 9 . The structure, grown on a semi-insulating GaAs substrate by molecular beam epitaxy, consists of twenty-five stages. Each stage includes a coupled-well active region separated by thick barriers. The coupled-well active region is engineered so that, at the threshold electric field E 1 and E 2 , levels are anticrossed such that
E 2 −E 1 =ΔE hk
where ΔE hk is the optical phonon energy. Barrier heights and well thickness are chosen such that both quantum wells have the same photoexcitation energy between ground and excited states such that:
E
3
−E
1
=E
4
−E
2
=ΔE
hv
=hc/λ
p
where ΔE hv is photoexcitation energy associated with the peak wavelength λ p . The ground state of the left quantum well is doped up to Fermi level E F which is located below E 2 .
E
F
<E
2
−E
1
During the transition, electrons in the E 1 ground state excite to the E 3 level by absorbing photons. As a result of Eq. 1, we can obtain a very short life time between E 3 and E 2 states since their energy separation is resonant with the optical phonon without any momentum transfer. For a L D =60 Å barrier separation, this life time is about τ 32 ≈0.6 picoseconds. Therefore, photoexcited electrons in the level E 3 will relax to E 2 and populate the ground state (E 2 ) of the right quantum well. The life time of the level E 2 is longer since it involves optical phonon emission (from E 2 to E 1 ) associated with a large momentum transfer. Now, these electrons can escape from the quantum well by absorbing a second photon and be collected as photocurrent.
The design and optimization of the proposed scattering enhanced double quantum well infrared detector is based on the balancing of the various transition processes inside the device as well as the coupling of the device to the environment. The device performance depends strongly on efficient coupling of the desired excitation path from the ground state via two photon absorption processes and one polar optical phonon emission process. Design of the two quantum well and central barrier widths will determine the efficiency of the polar optical phonon emission process. Processes that decrease the performance of the device can be classified into two groups 1) thermionic emission out of the quantum wells and 2) non-radiative recombination from the exited states out of the desired path back into the ground state. Acoustic phonon, polar optical phonon, and interface roughness scattering are expected to be major non-radiative processes.
The theoretical work proposed here will compute the various scattering and tunneling rates based on a quantum mechanical treatment of scattering Hamiltonians in a full bandstructure basis. Combined with a model for carrier capture and thermionic emission from the individual states in the double quantum well, a rate equation-based description of the electron transport through the structure will be developed. The composite output of the calculation will be the dark current, absorption linewidths, and signal-to-noise ratios. The device design will be aided by a graphical user interface that enables the entry and variation of structural data, material parameter data, applied bias, and incident photon flux. The device designer will be able to vary structural data, such as the width of a quantum well, and obtain fast feedback to achieve optimal designs.
Although this device concept reduces the quantum efficiency by a factor of 2 (two photons are required to get one electron out) or more compared to a typical QWIP, the reduction in dark current is expected to be much more than factor of 2. Depopulation of energy levels by using resonant phonon scattering is a proven concept. At typical operating temperatures (e.g. T>55 K for λ=15 μm detector), QWIP dark current is dominated by classical thermionic emission and thermal assisted tunneling which depends exponentially on barrier height from the ground state, i.e.
I QWIP α e −(Δ E b −E F )/ k B T
where T is the operating temperature, and k B is Boltzman's constant.
FIG. 10 shows ΔAE b and E F are quantum well barrier height and ground state Fermi energy, measured from the ground state. Even though, one can increase ΔE b to reduce the dark current, ΔE b is limited by the energy level difference between the ground and excited state, i.e. ΔE b ≈E 1 −E 0 . This requirement is very critical at longer wavelengths because photoexcitation energy decreases as wavelength increases (E 1 −E 0 ≈82 meV at λ≈15 μm). In order to optimize performance, QWIP structures are typically designed by placing the first excited state exactly at the well top, which is referred as a bound-to-quasibound quantum well. Dropping the first excited state to the well top allows maximization of the thermionic barrier without stopping photoexcited electrons escaping from the excited state to the continuum. Therefore, dark current for a bound-to-quasibound QWIP can be expressed as:
I QWIP α e −(Δ E hv −E F )/ k B T
However for the proposed structure effective thermal barrier height is:
ΔE b =E 4 −E 1 −E F ≈2·Δ E hv −·ΔE hk
Therefore, the dark current reduction factor can be estimated as: I DWELL I QWIP = - ( Δ E hv - Δ E hk ) / k B T
Where ΔE hk is optical phonon energy. For λp=15 mm detector, ΔE hv ≈82 meV, ΔE hk ≈36 meV and T=55 K: I DWELL I QWIP ≈ 1 1000
which is about a factor of 1000 in reduction of the dark current.
Numerous variations and modifications of the invention will become readily apparent to those skilled in the art. Accordingly, the invention may be embodied in other specific forms without departing from its spirit or essential characteristics. | A three-color QWIP focal plane array is based on a GaAs/AlGaAs material system. Three-color QWIPs enable target recognition and discriminating systems to precisely obtain the temperature of two objects in the presence of a third unknown parameter. The QWIPs are designed to reduce the normal reflection over a significant wavelength range. One aspect of the present invention involves two photon absorptions per transition in a double quantum well structure which is different from typical QWIP structures. This design is expected to significantly reduce the dark current as a result of higher thermionic barriers and therefore allow the devices to operate at elevated temperatures. The device is expected to be fabricate using a GaAs/Al x Ga 1−x As material system on a semi-insulating GaAs substrate by Molecular Beam Epitacy (MBE). | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 09/651,594, filed Aug. 30, 2000, now abandoned, which claims the benefit of U.S. Provisional Application No. 60/151,508, filed Aug. 30, 1999, each of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to the management of source and derivative data and, more particularly, to methods and apparatuses for managing source and derivative image data for efficient use and manipulation within a computer network environment.
BACKGROUND
[0003] The Internet is the largest network of computers. Large corporations and educational institutions may have their own networks of computers, which may themselves be part of, or apart from, the Internet. Digital data, stored on one or more computers (called “Source Data”), may be accessed by one or more other computers and altered by such other computer(s) to generate “Derivative Data”. Often times, the source data is typically modified by a computer other than the computer that is requesting the derivative data. The Derivative Data may be stored on one or more other computers, which may include all or some of the computers on which the Source Data were stored and all or some of the computers that altered the Source Data. When the Source Data is representative of an image, it is called Source Image Data and the altered data is called Derivative Image Data.
[0004] There are many well-known methods of creating Derivative Image Data (“DID”) from Source Image Data (“SID”). Many of these methods consist of applying one or more transformations, T(1), T(2), . . . T(n) to the SID. These transformations may act on one or more SID sets and produce one or more DID sets. For example, if the SID is a digital image with an even number of pixels in each row and an even number of rows, T(1) may be a transformation that “crops the source image to create a new image consisting of the upper right hand quarter of the source image”. If the SID is a digital image where each pixel consists of three 8 bit numbers, R, B, G, that indicate the red, blue and green intensity values, respectively, for each pixel, T(2) may be a transformation which “interchanges the R and B intensity values”. A derivative image may be created from a source image by performing T(1) and then T(2) and then T(1) on the SID. Other examples of image transformations are the rotation, scaling, filtering and image processing operations contained in Adobe's Photoshop software. Such methods are known as deterministically computable methods. Such methods generate a DID set from a specific set of SID sets by applying a specific set of completely defined transformations in a specific order. For example, if the SID set consisted of numbers and a transformation S was “multiply every other number by a random number generated by the local computer”, then this method would not be deterministically computable unless the method of computing the random number was also specified and reproducible.
[0005] There are many standard and proprietary formats for image data. Some data formats do not contain information that describes how the data are to be interpreted. For example, consider a data set D consisting of 512×512×8 bits of data. This data set D may represent a gray scale image with 256 gray levels at each of the 512×512 pixel sites or the same data set D may represent balances in bank accounts. Other formats of data include meta-data (that is data about the data) that enables proper interpretation of the data. For example, there may be a header (another data set) which is appended to the header of D, which is text and reads “the data following this text consists of 512×512 bytes of data, each byte of which represents an 8 bit gray level pixel value and the pixels are arranged in an array of 512 rows and 512 columns of pixels with the first pixel value being located at the upper left-hand corner of the image and the subsequent pixels filling the array across rows and down columns.” An alternative is to append a file name extension, such as .jpg, or .gif, which indicates that the data in the named file has a standard, well documented format either known to the public, or in the case of proprietary formats, to authorized users of the format. Many image formats use a combination of the file name extension and header data to provide interpretative information. For example, the jpg format includes a header structure and the header structure has a field in which users may insert data, such as a comment, which provides even more meta-data. Some fields of header data may be necessary for the format to conform to its specification and other fields may be optional.
[0006] When an application program is written, such as a program to display a .jpg image on a computer screen, the program may be written to ignore optional data in a header. An application program may still properly display the .jpg image, even if it does not use the optional data to display the image. Image data formats, which include header field(s) for data not required for use by an application program so it generates an image that conforms to the format specifications are termed herein as “commentable formats”. The element of commentable formats that is important for the present invention is that it provides a mechanism for a program to insert and make use of reasonably large data strings without interfering with the proper interpretation of the formatted data by another, independent program which cannot parse or use the data strings. Although only image data is discussed herein, those skilled in the art will immediately understand that the appended header may be replaced by any mechanism which provides a documented place for meta-data and that such formats include formats for video and audio data, 3-dimensional data such as for CAT-scans, computer graphic data, virtual reality data and such other forms of data that have commentable formats.
[0007] There are many methods that relate to the use of source and derivative images. For example, the Open Prepress Interface (“OPI”) specifies a mechanism for a user of a reduced size version (derivative) of a high quality original digital image (source) within compliant document creation programs to move the derivative around in the document (for example, for placement purposes) and then send the document, which includes a file pointer to the source image, to a printer. The printer then replaces the derivative image with the source image in the printed output. However, such methods do not include information as to how the derivative image was generated from the source image and the file pointer is not universal but specific to a particular file system.
[0008] There are many well known aspects to the management of digital data. One task may be to erase all digital data that has not been read or altered for a year and such tasks may be done efficiently. However, there are many valuable image management tasks which relate to the relationship of source and derivative images and that cannot now be done efficiently. For example, one of the most popular methods of generating images for the World Wide Web involves the use of Adobe's Photoshop program. Inside Photoshop, images are created in layers with, for example, one layer being a background photo (layer 1), another layer being an inset photo of a sports star (layer 2), another layer being a marketing brand icon (layer 3), another layer being a photo of a product (layer 4) and another layer being text (layer 5). A photo appearing on the Internet may consist of all layers superimposed on the previous one. One source-derivative data management task may be, for example, to replace all old brand icons appearing on such web images with new brand icons. Currently, except for looking (whether it is done by a person or by a computer image processing program) at every image on every web site (this approach is called the method of exhaustive search), there is no method for completing such a data management task. The method of exhaustive search, carried out by humans, is feasible only on small networks. However, there are not enough people to carry out an exhaustive search on the Internet within a time period that renders such a search useful to people and corporations. The method of exhaustive search, as carried out by computers, is only feasible when one imposes very restrictive conditions on the derivative data sets. For example, when brand images are arbitrarily rotated, scaled and filtered, even if such transformations are limited to those enabled by the Photoshop program only, no known computer program can identify such transformed brand images as being derived from source brand images.
[0009] What is needed is a system and method for identifying the source sets used to generate derivative images and the transformations used for generating such images.
SUMMARY
[0010] In general, the invention features a method and apparatus for processing derivative data sets generated by deterministically computable methods. The derivative data is managed in relationship to changes in source data or in relationship to new requirements for derivative data. For example, the derivative image data in a low resolution RGB JPEG format is appropriate for viewing on a computer monitor. If it becomes necessary to print the derivative data set on a different output device, the apparatus can generate a new, but similar, derivative data set from the source data that matches the resolution and color properties of the new output device.
[0011] In general, in one aspect, the invention features a data management system, including a process that contains a first data set, a first server associated with the process, the server including a processing engine, wherein the engine is adapted to process the first data set to form a second data set, a storage medium adapted to receive the second data set; and a second server adapted to distribute the second data set. The second server is not necessary for distribution of the second data set, this could certainly be one physical server. The entire system (repository, databases, transform engine & client applications) can be implemented on a single Windows PC.
[0012] In an implementation, the system includes a first database having at least one data structure associated with the first data set and a second database having at least one data structure associated with the second data set.
[0013] In another implementation, the system includes a data attachment associated with the second data set that identifies the second data set as a derivative of the first data set.
[0014] In still another implementation, the first and second data sets are images.
[0015] In another aspect, the invention features a method of managing data, including locating a first data set, transforming the first image into a second data set, while maintaining the first data set and processing the image for use on a network.
[0016] In an implementation, locating the first image includes searching for locating data associated with the first data set and retrieving the first data set based on the locating data.
[0017] In another implementation, transforming the first data set includes associating a tag with the second data set that identifies the second data set as a derivative of the first data set.
[0018] In another implementation, the tag is embedded in the second data set or attached to the second data set.
[0019] In another aspect, the invention features a data management method, including providing a first source data repository having at least one source data set, providing access to at least one user to the first source data repository, forming one additional data repository having a subset of source data from the first data repository, wherein the subset of data is provided from the user, receiving requests from the user in the additional data repository to form derived data sets from the subset of source data, selectively processing the requests and forming derived data sets in response to the requests.
[0020] In an implementation, selectively processing the requests includes determining whether the user is authorized to access the additional data repository, allowing the user access to the additional data repository if it is determined that the user has authorization and alternatively allowing the user to access the data repository.
[0021] In another implementation, the method includes determining whether source data in the data repository that corresponds to the subset of data can be accessed by the user.
[0022] In still another aspect, the invention features a repository or database containing original or source image data set(s), a processing engine capable of applying a sequence of one or more computationally deterministic transformations to one or more of the original data sets, producing a secondary or derivative image data set(s), a process whereby a GUID (globally-unique identifier) is produced and associated with each derivative image data set generated through the process, a “derivative data database” containing a record of each transformation sequence so that a pointer to the source image data set, and the sequence of transformations and all parameters describing each transformation are stored with the associated GUID, a process that, given only a GUID, can retrieve the transformation sequence stored in database and reinitiate process in order to exactly regenerate the associated derivative image data set originally produced in process, or given alternate parameters for any element of the transformation sequence originally used in process, can initiate process using a modified transformation sequence to produce a new derivative image data set.
[0023] In an implementation, the system maintains multiple revisions of original source image data sets so that the specific revision of the source image data used in a particular process is recorded in (each record of) the derivative data database, so that if given a GUID associated with a derivative data set is produced from an old revision of a source data set, the system can either reproduce the derivative data set exactly from the old revision of the source data set(s) or produce a new and unique derivative data set using the same sequence of transformations recorded in the derivative data database but starting with the now current source data set.
[0024] In another implementation, the system records additional data concerning the derivative data set(s) in the derivative data database such as but not limited to the intended usage for each derivative data set, an alternate or preferred source data set, combined with a corresponding transformation sequence for process, that could henceforth be used in place of the derivative data set associated with the GUID.
[0025] In another implementation, the source data set and the derivative data set is image data so that source data sets can be inserted into a process, or revised and reinserted into a process, as any common or custom image file format (JPEG, GIF, PNG, TIFF, Adobe Photoshop .PSD, Windows Bitmap, etc) and derivative image data sets can be exported to any common or custom image file format (JPEG, GIF, PNG, TIFF, Adobe Photoshop .PSD, Windows Bitmap, etc).
[0026] In still another implementation, multiple source image data sets can be combined through a sequence of transformations as in process to produce a derivative image data set.
[0027] In another implementation, the system includes one or more networked computers so that each GUID generated by a process can be combined with the networked host name (i.e. the Internet domain name) of the computer that maintains the derived data database, and be associated with the derivative image data set as a “tag” and an independent networked computer, connected to a common internetwork, that obtains the derivative image data set(s) along with the associated GUID(s)+host name, can connect to the computer specified in system a and request information concerning the derivative data set, and request that replica or similar derivative data be produced by system and delivered over the internetwork.
[0028] In another implementation, all computers within the system can exchange operational data using any common network protocol such as HTTP over TCP/IP, or over a proprietary network protocol.
[0029] In yet another implementation, derivative image data sets, exported in standard image file formats, contain the data as an “embedded tag” that exists in the following form: <tag start><tag GUID><origin server name><tag end>, where:
[0030] <tag start> and <tag end> are a fixed sequence of octets that are unlikely to occur in an image
[0031] <tag guid> has a defined format and is always the same number of octets
[0032] <server name> usually exists as a “fully qualified Internet domain name”
[0033] The total size for the sequence of <tag guid> and <server name> is limited to a finite number of octets.
[0034] So that, the tag data:
[0035] a. Is unobtrusive to applications that are unaware of the embedded tag
[0036] b. Is easily located and validated by applications seeking the tag data
[0037] c. Can easily be embedded in any commentable image file format
[0038] d. Can potentially be harmlessly appended to any image file format that does not normally allow for comments.
[0039] In another implementation, the data exists as a tag within an HTML or XML document which references the associated derivative image file in the form of a fully-qualified or relative URL (Universal Resource Locator)
[0040] In another implementation, a process searches through the contents of one or more standard web sites (most likely via HTTP), looking for standard image files. The process then examines each image that it finds looking for embedded tags, and records information concerning the location of each tagged derivative image in a database.
[0041] In another implementation, the system enables a user to determine the (Internet) location of each derivative image that was derived from a particular source data set. Such a system would enable an application to automatically and transparently update “all known” derivative images produced from old revisions of a recently updated source data set by way of a mechanism.
[0042] A system and method of the present invention uniquely identifies derivative images and determines their origin in a network environment such as the Internet. The invention generates a derivative image from the original source data and associates a “tag” with the new derivative image. The tag uniquely identifies the server that generated it, the source image it was derived from, and the tasks or transformations that were applied to the source image to generate the derivative. The tag typically does not contain a map of tasks that produced the derivative set, and points to a database record containing all relevant information that is needed to reproduce the derivative data set. These transformations, which include compression, scaling, indexing, and editing, take an image file in a variety of formats as an input and then provide as an output an optimally formatted, edited, enhanced version of the image.
[0043] The form of this tag logically resembles that of a URL, such as:
[0044] mbp://mediabin.iterated.com/lad29bf8dd121f2f3cef2c34ef1b2b3d
[0045] where the “mbp://” represents a hypothetical protocol—although HTTP or another standard Internet protocol may be used. Also, a specific protocol for accessing the derived image data need not be specified by the tag. The “mediabin.iterated.com/” represents the host or domain that generated the derivative image. The 16 bytes of hexadecimal data represent a universally unique identifier from which the specified host or domain controller determines or looks up the history of the image being managed in a database.
[0046] Although the preceding example represents static data embedded in a simple image file, the tag may represent the same sort of data in a different form that allows an object to be modified according to the requirements of the rendering device. The tag provides a pointer to the location of comprehensive information about the derivative image's origin.
[0047] A tag is preferably inserted into commentable derivative image data which includes pointers to the location of not only source data but to the location of the set of instructions by which the source data was transformed into the derivative data. When these addresses have the form of an Internet host name together with a GUID (global unique identifier), this method is transparent to applications operating on the data set and the local computer file system where the image and other data are stored. It is also possible that the tag data (source host name or domain name and GUID) is associated with the derivative image data set through methods other than embedding the tag in the derivative image file. For example, the tag can be included within an HTML or XML document that includes, or points to, the derivative image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] [0048]FIG. 0 illustrates an embodiment of a data management system;
[0049] [0049]FIG. 1 illustrates an embodiment of an operational portion of a data management system of the present invention;
[0050] [0050]FIG. 2 illustrates a flow chart of an implementation of generation and placement of derivative images;
[0051] [0051]FIG. 3 illustrates another embodiment of a data management system;
[0052] [0052]FIG. 4 illustrates a flow chart of an implementation of derivative image creation and placement;
[0053] [0053]FIG. 5 illustrates a flow chart of an implementation of global derivative image updating;
[0054] [0054]FIG. 6 illustrates another embodiment of a data management system;
[0055] [0055]FIG. 7 illustrates a flow chart of an implementation of source and derivative image updating;
[0056] [0056]FIG. 8 illustrates an overview of an embodiment of a business model;
[0057] [0057]FIG. 9A illustrates a prior art attempt to modify an image; and
[0058] [0058]FIG. 9B illustrates an implementation of modifying an image using the data management system.
DETAILED DESCRIPTION
[0059] Data Management Overview
[0060] [0060]FIG. 0 illustrates an embodiment of a data management system 10 . A client computer 12 is connected to a server 16 through a network 14 . The client 12 can download web pages from the server 16 . The requests for the web pages and the web pages themselves are delivered through network 14 . In this embodiment, a web page 18 residing on the client 12 is downloaded from the server 16 and can contain numerous pieces of information from data files such as image file 20 . In some instances, the client 12 can be related to the server 16 . For example, the server may be a corporate headquarters for a car manufacturer, and the client 12 may be a dealership. In such a situation, the client 12 may need access to one or more source files, such as file 20 , of the web page 18 . The file can be an image file, for example. The client 12 may want to access the file in order to edit it for a new application such as a print out for a flyer or for a software application to make the file 20 poster-size. If the file 20 was derived from an original source, then the file 20 is a derivative file. If the file 20 is an image file derived from a source image, then the image is a derivative image. As discussed above, the source image may have gone through several transformations to yield the derivative image.
[0061] Presently, if a client accesses a file, the file that is accessed is a web-ready file as described above. Such a file may have been modified from the original in such a way that when the file 20 is opened in an editor, much of the original information may have been lost. The information, such as resolution information, may have been lost due to any of the transformations that may have occurred to the file 20 such as compression or reduction.
[0062] In one embodiment, the client 12 is able to access a file 20 on the web page 18 for editing. However, if the client 12 desires to edit the file in some way, the client is able to access the original source file and not the derivative file. In some instances, the client 12 can access a source file 26 directly from the server's database 22 . This access is possible if the server 16 had given prior authorization to the client 12 to access the database 22 . However, the client 12 may not have been given this authorization and may encounter a firewall 30 when the client 12 tries to access the database 22 . In this situation, the client can attempt to access a central database 24 that has a copy 26 a of the source file 26 . The central database 24 is connected to an application service provider 28 . This application service provider 28 provides a process 32 to servers such as server 16 that allows access to source files so that original files can be edited for new derivative images, rather than using derivative images to make new derivative images, therefore losing information in preceding transformations. In some situations, the client 12 may not even be able to access the copy 26 a of the source file 26 from the central database 24 . In this situation, the client 12 has no access rights or authorization to the source file 26 .
[0063] There are several other situations in which a client 12 may want to access the source file 26 instead of the derivative file 20 . For example, if the derivative file 20 is an image, the client 12 may want to print the image to a printer. If the client prints the derivative image that is web-ready, the print out may be distorted because the image was not properly transformed to match the characteristics for a printer. Therefore, the client 12 can access either the server database 22 or the centralized database 24 for the source image and create a new derivative image (different from the derivative file 20 ) that is compatible with the printer.
[0064] The existence of a centralized application service provider 28 allows a central location for source images for several unrelated servers. This centralized location allows servers such as server 14 as well as related clients such as client 12 to remain as thin as possible. The centralized server 28 serves at least two basic functions. It initially provides the process 32 to the servers that desire to have the functionality of creating several derivative images 34 using a single source file 26 . In this way a server such as server 16 can provide source image 26 access to one or more clients such as client 12 , from database 22 .
[0065] Another function of the centralized server is to provide centralized database 24 access to servers such as server 16 . This centralized access to database 24 allows copies of source files to reside on the centralized database.
[0066] In an implementation, the owner of server 16 can contract with the owner of the server 28 and database 24 for the process 32 and for the service which provides access to the central database 24 .
[0067] In another implementation, when the client successfully accesses a source file, an authentication process is also accessed which verifies that the source file is the authentic source file associated with the derivative image that the client 12 used to access the source file. This authentication can be accomplished by use of a tag—that is associated with the derivative file. A detailed description of the tag is discussed below.
[0068] Data Management Operation
[0069] [0069]FIG. 1 illustrates an embodiment of an operational portion of a data management system 100 . The system 100 is used to manage derivative image data that has been derived from source image data. A shared file system 105 can store numerous source images, each respectively associated with an image file 110 . A process, which is described in detail below, can be used to transform the source image into one or more derivative images (for example an image JPEG associated with a file 115 ) that are “web-ready”. The derivative image file 115 can then be transferred to a web server 120 where it is made available to a user (not shown). The web server 120 can be a part of any network server, Local Area Network (LAN) and the like.
[0070] [0070]FIG. 2 illustrates a flow chart of an implementation of derivative image generation and placement process 200 . The user or automatic process locates 205 a source image (that can be of any image format (e.g., .JPG, .GIF, .TRG, .BMP and the like)). The system then creates 210 a web-ready derivative of the source image. Typically the derivative is of any image format (such as .JPG) in which an embedded tag can be added to the format. In one embodiment, this embedded tag enables the process 200 to locate the source image and recreate a similar web-ready derivative from the original source image at a future time.
[0071] The derivative image is copied 215 to a web server (e.g., web server 120 in FIG. 1) and a standard HyperText Markup Language (HTML) document that references the web-ready image using a standard image tag is created 220 . In an implementation, a standard HTML format is used, typically like the following:
[0072] [std_web_page.html]
[0073] <p> This html page was authored using a standard HTML editor. </p> <img src=“hnage.JPEG” width=“240” height=“ 190 ”></p>
[0074] The image tag can specify dimensions that are different from the physical pixel dimensions of the web-ready image.
[0075] The HTML is then examined to locate 225 the web-ready image containing the embedded tag. The process 200 then rebuilds 230 a new web-ready image from the source image based on the parameters of the standard HTML image tag. Finally, the process 200 writes 235 the newly created web-ready image to a storage location on a web server (typically overwriting the original derivative image whose physical dimensions did not match the dimensions specified by the image tag). This process may be repeated 240 as necessary.
[0076] [0076]FIGS. 1 and 2 describe the basic approach of the hardware and software involved with derivative image management. The following figures illustrate further specific embodiments of derivative image management.
[0077] [0077]FIG. 3 illustrates another embodiment of a data management system 300 . Any web processing application 305 is connected to an image repository and processing server 310 . The server 310 includes an image task controller 311 and processing engine 312 . The image task controller 311 and processing engine 312 work in conjunction to process the source images to create new derivative images. The image repository and processing server 310 is connected to a web server 315 that is typically the ultimate location for the derivative image to be distributed. The web processing application 305 is typically connected to a source image repository database table 330 that locates source images for use in the application 305 from the source image repository 320 that is also connected to the image repository and processing server 310 . A derivative image database table 325 is connected to the image repository and processing server 310 and stores the derivative image metadata. Although not shown, the derivative image database table can also be connected to the web processing application 305 .
[0078] The data management system 300 can contain a process for derivative image creation and placement. FIG. 4 illustrates a flow chart of an implementation of a derivative image creation and placement process 400 . The system 300 first examines the website and the web page to locate 405 and identify a source image location and the associated requirements of that image. Requirements typically are the needed characteristics of a derivative image, for example, file format, pixel dimensions, color space and the like. Next the image is examined 410 to select desired image elements and layers, such as a crop region. The source location is typically determined from the source image repository database table 330 and retrieved from the source image repository 320 (as discussed below). The process generates and issues 415 a derivative image request to the image repository and processing server 310 . Typically the image request contains several elements such as, but not limited to: a source image ID, required derivative image attributes (image elements, color space, crop region, scale factor, file format and the like) and the derivative image destination (Universal Resource Locator (URL) for HTTP post, file name and location, and the like).
[0079] The source image is then retrieved 420 from the source image repository 320 . Typically, the image data is the form of pixel data. The image is transformed 425 to the requested derivative image parameters. In addition, the unique tag is applied and the derivative image is created. Next the post-tagged image is moved 430 as needed, typically to the web server 315 . As mentioned above the format is a URL and updated HTML. The derivative metadata is written 435 to the derivative image database table 325 . Optionally, the source image metadata is updated 440 to indicate that a derivative image has been produced and written back to the source image repository database table 330 . The derivative image database record contains a reference to the source image and the source image version. A report detailing which images have been derived from a given source image can be generated. This process can be repeated 445 as necessary.
[0080] The system 300 can also be used in a global derivative image updating process. FIG. 5 illustrates a flow chart of an implementation of a global derivative image updating process 500 . This process 500 is typically used to update derivative images that already have been tagged. The process first locates 505 tagged derivative images, which can be located on the web server 315 . The derivative image metadata within the derivative image database is examined 510 to determine if derivatives were created from current source image versions. Derivative image requests can then generated and issued 515 to update. The requests typically contain, but are not limited to the following elements: target image attributes (e.g., update derivatives) and target image destinations (URLs for HTTP Post, filenames and locations and the like). The source image data is then retrieved 520 from the source image repository 320 . The image is then transformed 525 to new derivative image parameters, unique tags are applied and the image derivatives are created. The post-tagged images are moved 530 typically to URLs on the web server 315 . The derivative image metadata is written 535 to the derivative image database table 325 and the source image metadata is updated 540 in the source image repository database table 330 . The user can repeat 545 the process 500 as needed.
[0081] [0081]FIG. 6 illustrates still another embodiment of a data management system 600 . This system 600 can be used with other derivative image management processes (discussed below). An image editing application 605 is associated-with an image repository and processing server 610 . The image repository and processing server includes an image task controller 615 and processing engine 616 used to process the images. Also associated with the image repository and processing server 610 is an image repository and processing client application 640 , which typically handles additional commands. A web server 620 is connected to the image repository and processing server 610 . A document storage unit 645 is typically a file server storage containing compound files containing tagged derivative image files. A source repository database table 625 and source image repository 630 are connected to the image repository and processing server 610 . A derivative image database table 635 is also connected to the image repository and processing server.
[0082] The system 600 can be used to update both source and derivative images. FIG. 7 illustrates a flow chart of an implementation of a source and derivative image updating process 700 . First the process 700 browses the source image repository 630 and retrieves 705 the image from the repository 630 . The source image is updated 710 and checked back into the repository 630 creating a new version. The updated source image is located in the repository 630 , typically by the image repository and processing client 640 . The client 640 then issues an “update known derivatives” command and retrieves 715 the updated image from the repository 630 . The image is transformed 720 to target parameters, wherein unique tags are applied and the derivative image is created. The post-tagged image is moved 725 to the URLs (as discussed above). The updated derivatives are exported 730 to external compound files stored in the document storage unit 645 . The derivative image metadata is written 735 to the derivative image database table 635 . Finally, the source image metadata is updated 740 . This process 700 can be repeated 745 as needed.
[0083] In general, the systems and methods described above provide for applications that can transparently manage image resolution and color characteristics across numerous applications running on machines connected to a common network (such as the Internet or private intranet). For example, a plug-in, or “COM add-in” for Microsoft® Office can provide Office applications with a mechanism to connect to, browse and search a data management system server for a desirable source image, define an optional sequence of transformations and parameters (crop region, layer selections, resolution, color, filters, target file format and the like) into a document. Each placed image object is identified with a tag that identifies the data management server or entity that produced the image, and a GUID.
[0084] The originating data management server, when presented with a derivative image GUID by a client application, can offer comprehensive information about the derivative image, including but not limited to: source image GUID; secondary, tertiary . . . source image GUID(s); source image revision(s) used to produce DI; source image current revision(s); retrieval Task GUID (if applicable); retrieval Task contents (all transform steps with parameters); derivative image saved to location; derivative image creation server name (for example, server's Internet Domain Name); derivative image creator (name of user that issues request for DI); derivative image creation date and time; derivative image comment or intention; and alternate derivative image GUID record (i.e. this GUID is obsolete, recommend this GUID).
[0085] The client application can also make requests for and receive new image data, to retrieve a duplicate derivative image, an updated derivative image from more recent revisions of source image(s), or to render a similar derivative image for an arbitrary output device.
[0086] In another embodiment, as shown generally in FIG. 8, one technique allows an offer to the data management system's software licensees enabling them to establish a relationship with an ASP that provides hosting for “replica” data management system data and services. The ASP-hosted replica can contain both the data management system repository (source image database: image and metadata) and DID contents. The service also offers the option of maintaining DID records at a well-known host address such as: master.mediabin.net. Because each derivative image GUID is indeed “globally unique”, a query to master.mediabin.net can resolve any derivative image GUID that has been replicated to an ASP that is associated with mediabin.net, and has been flagged to publish a “GAR” (Globally Accessible Reference) at master.mediabin.net.
[0087] Such a service can enable any number of applications, such as a COM add-in for Microsoft Office, a plug-in for Adobe Acrobat, or a stand-alone application, if having failed in an attempt to contact the host name identified by the derivative image tag, to contact master.mediabin.net with the derivative image GUID in question. If a globally accessible reference exists for the GUID in question, and the requesting user passes authentication requirements, then the ASP's data management system server can fulfill requests for related image data.
[0088] Customers may indicate that modified or updated derivative image data can be requested from master.mediabin.net by anonymous users, or they may require that users supply a digital signature or username and password. These access requirements can be determined globally or on an image-by-image basis.
[0089] This business model presumes that customers obtain a software license for a local data management system server, and subscribe to the hosted service. A partial list of how a customer may be charged for this service can include, but is not limited to, the following: local data management system software license fee; monthly or quarterly fee per megabyte of data maintained for them at a data management system site; and monthly or quarterly fee per image transaction.
[0090] As an example of the methods and systems described above, a comparison of a prior art system to create a derivative image from a source image and of the data management system used to create a derivative image from a source image is shown. This example illustrates the value of being able to regenerate an image from an original source, rather than generating a new image from a derivative of the original source image, which may not include information necessary for the creation of the new derivative image.
[0091] As a category of web content, images represent a special challenge. Unlike data from conventional databases, application source code, promotional text, XML and HTML, web images cannot be directly edited and reused. The vast majority of images used on web sites are generated to meet specific size and format requirements from an original source image of another format—typically an Adobe Photoshop document that was worked with during the creative process.
[0092] [0092]FIG. 9A illustrates a prior art attempt to modify an image. Presently, it is very difficult to produce a 16 million-color, 400 pixel-wide JPEG image starting with a 64 color, 100 pixel-wide GIF image (from a web page) using Photoshop. An original GIF image 905 is modified in Adobe® PhotoShop to produce the resulting image 910 .
[0093] [0093]FIG. 9B illustrates an implementation of modifying an image using the data management system of the present invention. A derivative image 920 is produced from a source image 915 using the methods and system described above.
[0094] In view of the foregoing detailed description of preferred embodiments of the present invention, it readily will be understood by those persons skilled in the art that the present invention is susceptible to broad utility and application. While various aspects have been described in the context of HTML and web page uses and in the context of management of image data, the aspects may be useful in other contexts as well. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Furthermore, any sequence(s) and/or temporal order of steps of various processes described and claimed herein are those considered to be the best mode contemplated for carrying out the present invention. It should also be understood that, although steps of various processes may be shown and described as being in a preferred sequence or temporal order, the steps of any such processes are not limited to being carried out in any particular sequence or order, absent a specific indication of such to achieve a particular intended result. In most cases, the steps of such processes may be carried out in various different sequences and orders, while still falling within the scope of the present inventions. In addition, some steps may be carried out simultaneously. Accordingly, while the present invention has been described herein in detail in relation to preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended nor is to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | A method and apparatus for managing source and derivative data is disclosed. Source data, typically image data, is centralized in a database and derivative data sets are formed from the source data. When it is desired to modify a derivative data, the source data can be accessed and modified to form a new derivative data set instead of modifying the already derived data set. In this way source data integrity is maintained. Derivative data sets are identified and tags are associated with new derivative images. The tag can be embedded in the derivative data or associated with the image as an attached element. The tag identifies information such as the server that generated the derivative image, the source image and any tasks or transformations that were applied to the source image to generate the derivative data. Users of source data can be given access to a central source data repository and access privileges can be assigned. In this way a number of users can access the source files and globally modify all derivative images by changes in the source file. | 8 |
BACKGROUND OF INVENTION
1. Field of Invention
The present invention pertains to the art of washing machines, and more particularly, to a control system for braking an inner tub of a washing machine through a critical speed range within which an out-of-balance condition could occur, such that the washing machine is not exposed to high vibration levels.
2. Discussion of Prior Art
Typical washing machines perform a wash cycle by agitating or tumbling a load of clothes bathed in a water or water/detergent solution within an inner tub. After the wash cycle has completed, a spin cycle, including an extraction phase and a deceleration phase, is required. Most machines perform this cycle by spinning the inner tub at a high rate such that centrifugal forces cause the water or water/detergent solution to separate from the clothes. After a predetermined period has elapsed, drive to the inner tub is disrupted whereby the inner tub is slowly brought to a stop.
It is well known in the art that, prior to the extraction or dehydration phase, the clothes can become unevenly distributed within the inner tub. During the extraction phase of the spin cycle, the uneven distribution of the clothes results in an out-of-balance condition which causes excessive vibration of the machine. For this reason, it is known to incorporate out-of-balance sensors in washing machines to determine the presence of such a condition which can be counteracted such that the effects caused by the vibrations are reduced. While these corrective measures are effective, they focus on the extraction phase of the spin cycle, as opposed to the deceleration phase of the cycle. However, during the deceleration phase, an out-of-balance condition can cause the machine to experience similar vibration problems as during the extraction phase of the spin cycle. Accordingly, based on at least these reasons, there exists a need in the art for a braking system which will effectively and efficiently reduce the effects of vibration on a washing machine, thereby enhancing the effective life of the machine and protecting its various components.
SUMMARY OF THE INVENTION
The present invention is directed to a system and method for effectively braking an inner tub or spinner of a washing machine following an extraction phase of a spin cycle to reduce the amount of time the inner tub is near the resonant frequency of the machine. Experience has shown that an out-of-balance condition will occur within a discrete or critical speed band during deceleration (assuming a generally consistent load size). Therefore, if the inner tub is caused to rapidly pass through the critical speed band during braking, the effects of high vibrations due to an unbalanced load is substantially eliminated. To this end, in accordance with the invention, a control system is incorporated into the washing machine to rapidly decelerate the inner tub through the critical speed band, preferably by applying a short burst of braking force, e.g., a pulsed braking force, to reduce the impact on electronic control components.
In accordance with the invention, an out-of-balance sensor is provided to sense the onset of an unbalance condition. The sensor will signal a controller which will operate a brake to rapidly decelerate the inner tub. More particularly, in one preferred embodiment, the controller is configured to intermittently operate the brake to slow the inner tub through the critical speed band such that component life can be extended. In another preferred embodiment, the brake control of the present invention is incorporated into systems having a mechanical brake. As mechanical braking systems are exposed to potential damage when subjected to excessive or extreme out-of-balance conditions, the present invention preferably provides for intermittent operation of the mechanical brake to aid in handling unbalanced loads.
In a still further preferred form of the embodiment, the control system of the present invention will “learn” the location of the critical speed band during a spin cycle in which an out-of-balance condition is likely to occur for any given load size. The location will be stored in a memory including a “look-up” table such that the control will activate the brake over a known discrete speed band in order to reduce the impact of an out-of-balance condition.
Based on the above, it should be apparent that the system of the present invention relies upon one or more specific dynamic variables of the washing machine in order to accurately and effectively control the braking of the inner tub, such that the washing machine is not exposed to excessive vibrations. In any event, additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of preferred embodiments when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a horizontal axis washing machine incorporating the braking control system of the present invention; and
FIG. 2 is a partially cut away view of a vertical axis washing machine, including a spherical spinner, multiple agitators and a direct drive system, incorporating the braking control system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With initial reference to FIG. 1 , an automatic horizontal axis washing machine incorporating the braking control system of the present invention is generally indicated at 2 . In a manner known in the art, washing machine 2 is adapted to be front loaded with articles of clothing to be laundered through a tumble-type washing operation. As shown, automatic washing machine 2 incorporates an outer cabinet shell 5 provided with a front door 8 adapted to extend across an access opening 10 . Front door 8 can be selectively pivoted to provide access to an inner tub or spinner 12 that constitutes a washing basket within which articles of clothing are laundered.
As is known in the art, inner tub 12 is formed with a plurality of holes 15 and multiple, radially inwardly projecting fins or blades 19 are fixedly secured to inner tub 12 . Inner tub 12 is mounted for rotation within an outer tub (not shown) which, in turn, is supported through a suspension mechanism (also not shown) within cabinet shell 5 . Inner tub 12 is mounted within cabinet shell 5 for rotation about a generally horizontal axis. A motor 27 , preferably constituted by a variable speed, reversible electric motor, is mounted within cabinet shell 5 and adapted to drive inner tub 12 . More specifically, inner tub 12 is rotated during both wash and rinse cycles such that articles of clothing placed therein actually tumble through either water, a detergent/water solution, or another washing fluid supplied within inner tub 12 .
The general construction and basic operation of washing machine 2 is known in the art and not considered an aspect of the present invention. Therefore, a full description of its construction will not be set forth here. However, for the sake of completeness, automatic washing machine 2 is also shown to include an upper cover 42 that provides access to an area for adding detergent, softeners and the like. In addition, an upper control panel 45 , including an LCD touch screen display 50 , is provided for manually setting a desired washing operation.
The present invention is particularly directed to the manner in which a rotational speed of inner tub 12 is controlled during a critical period following an extraction phase of a spin cycle. To this end, FIG. 1 also illustrates one preferred control system embodiment in accordance with the present invention. As shown, washing machine 2 incorporates a central processing unit (CPU) 60 which preferably includes a memory 62 . As will also be detailed fully below, CPU 60 functions to regulate a brake control 65 for inner tub 12 . In the embodiment shown, CPU 60 is adapted to receive signals from an inner tub speed sensor 80 and an out-of-balance sensor 85 . As will also be detailed more fully below, CPU 60 actually functions to regulate brake control 65 , drive controls 90 and, at least indirectly, motor 27 . As further discussed more fully below, CPU 60 can receive signals from a load sensor as generally indicated at 92 . At this point, it should be noted that speed, out-of-balance, and load sensors for washing machines are well known in the art. In any event, the particular construction of each of these sensors is not important in connection with the present invention and therefore will not be detailed further here.
After the articles of clothing placed within inner tub 12 for laundering are subjected to a washing phase wherein the clothes will be tumbled within inner tub 12 , a spin cycle of an overall washing operation will be initiated. A similar spin cycle will also be performed following each rinse cycle. In any event, during an extraction or dehydration phase of each spin cycle, inner tub 12 will be rotated at relatively high speeds, e.g., speeds up to and exceeding 700 rpm as is known in the art, such that the water or water/detergent solution is caused to separate from the clothes. After extraction, a deceleration phase takes place wherein drive to inner tub 12 is terminated through drive control 90 . During the extraction phase, out-of-balance sensor 85 can be used to monitor for the onset of an out-of-balance condition. That is, if the clothes are unevenly distributed, out-of-balance sensor 85 will send a signal to CPU 60 . If the out-of-balance condition exceeds a predetermined threshold, CPU 60 can respond by modifying the operation of washing machine 2 , such as by lowering the maximum rotational speed for inner tub 12 for future cycles, as known in the art.
In any event, after the water or water/detergent solution is extracted from the clothing, a deceleration period for inner tub 12 is initiated. Therefore, motor 27 will be deactivated through drive control 90 and inner tub 12 is caused to decelerate. It is at this point that the present invention is actually employed. In accordance with the invention, as inner tub 12 decelerates, out-of-balance sensor 85 continuously monitors for the presence of an unbalanced condition. When out-of-balance sensor 85 detects an unbalanced condition during this deceleration phase, a signal is sent to CPU 60 . Essentially simultaneously with the receipt of the out-of-balance signal, CPU 60 will send a braking signal to brake control 65 in order to rapidly reduce the rotational speed of inner tub 12 . In general, experience has shown that a critical speed band will exist over an intermediate portion of the deceleration phase. It is during this portion that out-of-balance conditions are prevalent based on an average load and machine design parameters. In any event, as signals are continuously received from out-of-balance sensor 85 , brake control 65 need only be activated by CPU 60 through the critical speed band.
Most preferably, the signals received from out-of-balance sensor 85 reflect an incipient out-of-balance condition such that an actual state of unbalance need never actually be reached. In accordance with the embodiment of FIG. 1 , activation of the brake preferably constitutes altering the operation of motor 27 . More specifically, motor 27 is either operated in reverse, or at a speed substantially lower than the current speed of rotation of inner tub 12 , in order to rapidly reduce the rotational speed of inner tub 12 through the speed range that exhibits the out-of-balance condition. Regardless, instead of simply allowing inner tub 12 to coast to a stop or applying some constant braking force, the present invention assures that the speed of inner tub 12 is rapidly reduced through the critical speed band or range during which an out-of-balance condition would exist.
Although CPU 60 could operate in accordance with the invention based only on the signals received from out-of-balance sensor 85 for a current washing operation, speed sensor 80 also preferably sends signals representative of the speed at which the unbalanced condition occurs. In accordance with a preferred embodiment of the invention, the unbalance and speed signals are stored in non-volatile memory 62 for later use. That is, the stored information is used in connection with the invention to better determine an incipient unbalanced condition. In general, as indicated above, a substantially consistent critical speed range will be established for an average load size and a given washing machine construction/operation. In any event, by storing this information, CPU 60 can actually contain a “look-up” table used to anticipate an out-of-balance condition and take pre-unbalance measures to avoid the condition.
Of course, tests could be simply run for a particular washing machine, with CPU 60 having pre-stored in memory 62 the critical speed range for the application of rapid deceleration. Therefore, CPU 60 effectuates braking when inner tub 12 approaches an unbalanced state based on “learned” parameters, with these parameters either being learned in pre-testing prior to selling washing machine 2 to a consumer or during actual use by the consumer. As indicated above, CPU 60 can also receive signals from and store in memory 62 the weight of a particular washing load. In this case, over time, CPU 60 will acquire a plurality of speed and load parameters which relate to sensed out-of-balance parameters. This information can readily be used to identify a particular critical speed band for rapid braking dependent on the weight of the load. Therefore, in this manner, a critical speed band can be established for discrete load weights such that braking is achieved without exposing the machine to any undue vibration.
As indicated above, the preferred embodiment disclosed with reference to FIG. 1 controls motor 27 to establish the required braking. However, other braking arrangements could be equally employed. FIG. 2 depicts a vertical axis washing machine 100 which utilizes another type of braking arrangement. As the general structure and operation of washing machine 100 are known in the art (details being found in U.S. Pat. Nos. 5,829,277 and 6,220,063 which are incorporated herein by reference), these details will not be reiterated here. However, washing machine 100 is shown to include a generally spherical inner tub 110 , a substantially spherical outer tub 111 , and a control panel 113 . A pair of agitators 115 are mounted within inner tub 110 and are provided to cause clothes 120 to effectively shift within inner tub 110 during a washing operation. Inner tub 110 is drivingly connected to a motor 130 through a driveshaft 135 . More importantly, in connection with the present invention, washing machine 100 is shown to include a mechanical braking system including a brake disc 145 and a brake caliper 150 .
In a manner corresponding to that set forth with respect to the first embodiment described above, washing machine 100 can be controlled to rapidly brake through a critical speed band or range during a deceleration phase of a spin cycle. Due to the directly analogous structure and function with the embodiment of FIG. 1 , common reference numerals have been utilized in FIG. 3 to depict the corresponding structure. In any event, the main difference between the embodiment of FIG. 1 and that of FIG. 3 is that brake control 65 controls caliper 150 in the latter embodiment. Since, in all other respects, the two embodiments are the same, a complete reiteration of the overall operation will not be provided here. Instead, it is simply important to note that the invention can be applied to both vertical and horizontal axis washing machines and the braking function can be performed in various ways. Therefore, it should be realized that the examples set forth herein are not intended to limit the methods of or structure for braking that can be used in connection with the present invention. It should also be realized that the braking operation can be achieved through the use of a consistent or uniform braking force, or an intermittent force could be applied through the critical period. In any event, the invention is only intended to be limited by the scope of the following claims. | An inner tub of a washing machine is rapidly braked during a portion of a deceleration phase following an extraction phase of an overall spin cycle. A controller establishes the braking operation over a critical speed band or resonant frequency zone during which excessive vibrations would be developed. The critical speed band is preferably determined based on one or more signals received from speed, load, and/or out-of-balance sensors. | 3 |
[0001] This application is the U.S. national phase application of PCT International No. PCT/EP2005/051329, filed Mar. 23, 2005, which claims priority to German Patent Application No. DE 10 2004 014 175.4, filed Mar. 23, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to a system for driver support carrying out assist functions in a motor vehicle for supporting the driver in stopping and starting maneuvers, which are activated depending on a first comparison between at least one driving state parameter and a threshold value and/or based on first actuating signals from an actuating means operable by the driver.
[0004] 2. Description of Related Art
[0005] A large number of different electronic assist functions are known to support a driver of a motor vehicle in starting and stopping maneuvers. In order to prevent the vehicle from rolling rearwards during a starting maneuver, e.g. starting aids are employed where brake pressure is adjusted in the wheel brakes during standstill of the vehicle, which is automatically reduced during the starting maneuver. Customary names of starting aids of this type are hill holder system or Hill-Start-Assist-System (HAS System). Further, it is e.g. known to automatically activate an electric parking brake of the motor vehicle when it is detected that the vehicle is being parked, and to release the electric parking brake when a desire of the driver to start is detected.
[0006] The known assist functions are designed as independent functions which respectively include an own activation logic and a control of their own calculating the brake pressure demand. Thus, it is principally possible that several assist systems of this type are activated at the same time. As this occurs, there may be a multiple calculation of a brake pressure demand, with the result of an unnecessarily high expenditure in realizing the systems.
[0007] Especially the fact that in different assist systems normally different conditions for detecting driving situations such as a starting maneuver are checked, or that the existence of conditions is identified by way of difference threshold values, the different assist systems often calculate different pressure demands. Above all when there is a large number of assist systems of this type in a motor vehicle, the consequence may be an erroneous control of the brake system and, hence, impairment of vehicle safety.
SUMMARY OF THE INVENTION
[0008] In view of the above, an object of the invention involves realizing a reliable and safe control of the brake system also in the event that a large number of assist functions are performed in order to support the driver in stopping and starting maneuvers in a motor vehicle.
[0009] According to the invention, the system for driver support carrying out assist functions in a motor vehicle in order to support the driver in stopping and starting maneuvers, which are activated depending on a first comparison between at least one driving state parameter and a threshold value and/or based on first actuating signals from an actuating means operable by the driver is characterized in that a control unit determines a vehicle state by means of another comparison of at least one driving state variable with a predetermined threshold value and/or based on additional actuating signals of the actuating means, that the control unit checks whether at least one assist function is activated, and that the control unit controls the brake system of the vehicle depending on the detected vehicle state when at least one assist function is activated.
[0010] Advantageously, the invention uses a control unit, which performs both the detection of the vehicle states and the control of the brake system of the vehicle. The individual assist functions are maintained within the limits of the invention so that the vehicle driver can activate or deactivate the individual functions in order to set the degree of desired assistance according to his or her requirements.
[0011] Thus, a system is provided with a central control unit, i.e. being equal for all assist functions of the described type, which detects the vehicle states and performs the control of the brake system. However, brake interventions are carried out only if at least one of the assist functions is activated.
[0012] The invention uses the knowledge that the different assist functions in a defined vehicle state, such as the vehicle state ‘hold’, basically found on identical brake force demands which are determined by the central control unit in the system of the invention and are introduced into the brake system. Above all, however, the control unit allows a determination of transitions between different vehicle states being uniform for all assist functions, so that a uniform, reliable and safe control of the brake system is safeguarded when performing the assist functions.
[0013] In a favorable embodiment of the invention, it is arranged that the vehicle state is determined depending on a comparison between the vehicle speed and/or the vehicle acceleration with a threshold value.
[0014] In another favorable embodiment of the invention, the vehicle state is detected depending on an actuating signal of a brake actuating means operable by the driver and/or a driving engine control means.
[0015] Preferably, the actuating signals are detected by sensors mounted at the actuating means.
[0016] An assist function is advantageously activated depending on an actuating signal of a brake actuating means operable by the vehicle driver and/or a driving engine control means or depending on an actuating signal of an activation means operable by the driver.
[0017] The activation means may e.g. concern a switch for activation of a defined assist function, which switch is operable by the vehicle driver.
[0018] In a particularly favorable embodiment of the invention, the control unit is configured as a state machine. It is preferably provided in this case that a vehicle state is detected by examining in another vehicle state whether there is a transition condition for a state transition, and a state transition takes place when the transition condition is satisfied.
[0019] Preferably, the existence of a transition condition is detected by way of the additional comparison between at least one vehicle state variable and a predetermined threshold value and/or by way of the additional actuating signals of an actuating means operable by the driver.
[0020] In an especially favorable embodiment of the invention, exactly one vehicle state is established which is selected from one of the following vehicle states: creep, stop, hold stationary, park/secure, start up.
[0021] In a suitable embodiment of the invention, the control unit controls or regulates the brake system of the vehicle depending on the activated assist function.
[0022] This is favorable above all when different control/regulating demands would result with respect to different assist functions that can be activated in a defined vehicle state.
[0023] Preferably, the system comprises an arbitration unit, which detects depending on which activated assist function the control unit controls the brake system when several assist functions are activated in a vehicle state.
[0024] This is favorable when several assist functions are activated in a vehicle state, which have as a result different control/regulating demands.
[0025] Advantageously, the brake force is increased in the vehicle state ‘stop’, and the rate of change of the brake force is defined depending on the activated assist function and/or the assist function determined by the arbitration unit.
[0026] It is then provided in suitable embodiments of the invention that brake pressure is built up in a service brake system and/or a parking brake system is activated in the vehicle state ‘stop’ in order to increase the brake force.
[0027] Preferably, the brake force is maintained or a predetermined brake force is adjusted in the vehicle state ‘hold’.
[0028] In a favorable embodiment of the invention, the brake force which must be built up in the vehicle state ‘hold’ is defined depending on a longitudinal inclination angle of the vehicle.
[0029] It is further preferred that the brake force is reduced in the vehicle state ‘start up’.
[0030] In a favorable embodiment of the invention, in the vehicle state ‘uphill starting’ the brake force is reduced depending on a result of a comparison between a downhill force and a driving power of the vehicle.
[0031] Preferably, the parking brake is activated in the vehicle state ‘park/secure’.
[0032] In another preferred embodiment of the invention, it is arranged that at least one of the following assist functions is performed: a function for the active stop and start-up, a dynamic brake function, a function for the active vehicle hold, a traffic jam assist function, a function for the automatic release of the parking brake in a start-up maneuver, and a hill start assist system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Further advantages, special features, and suitable improvements of the invention can be seen in the written description and the subsequent illustration of preferred embodiments, making reference to the Figures.
[0034] In the drawings:
[0035] FIG. 1 shows a survey of the vehicle states which are distinguished in a preferred embodiment of the invention; and
[0036] FIG. 2 is a state diagram in which especially possible transitions between the vehicle states illustrated in FIG. 1 are shown.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] A preferred embodiment of the system of the invention for the driver support is referred to as standstill manager (SSM) in the following. The SSM controls the brake system of the vehicle, which preferably comprises a service brake system and an electric parking brake.
[0038] The service brake system of the motor vehicle e.g. concerns a hydraulic or electrohydraulic brake system, in which brake pressure is built up in a hydraulic fluid in a master brake cylinder and is transmitted to wheel brake cylinders being arranged at the wheels of the vehicle.
[0039] Favorably, the service brake system also includes an energy supply that is controllably by the SSM and permits building up the brake pressure in the master brake cylinder or in the wheel brake cylinders, respectively.
[0040] The wheel brake cylinders further connect to the master brake cylinder by way of separating valves controllable by the SSM so that the brake pressure in the wheel brake cylinders can be preserved by closing of the valves. Alternatively, the brake pressure can also be maintained by an active booster.
[0041] The vehicle driver controls the service brake system using a brake actuating means, which is usually designed as a pedal, which is mechanically coupled to the master brake cylinder by way of a brake booster or, in the case of an electrohydraulic brake system, is equipped with a pedal travel sensor, whose signals are detected by a control unit and serve to control a hydraulic unit. The brake pressure in the wheel brake cylinders is measured by means of pressure sensors.
[0042] However, the invention is not limited to this embodiment of the service brake system. The expert in the art rather notices that the invention can be transferred in a similar manner also to other brake systems.
[0043] The electric parking brake comprises, for example, duo servo or combined-caliper wheel brakes being arrested by actuators. The actuators are actuated directly at the brake caliper either by means of an electric motor via Bowden cables or by means of appropriate mechanics or hydraulics. The vehicle driver controls the electric parking brake preferably by means of a switch, which is arranged inside the motor vehicle. Besides, the motor vehicle is equipped with a driving engine, e.g. designed as an internal combustion engine, which generates an engine torque being transmitted to the drive wheels via the driving track of the vehicle. The engine is controlled by the vehicle driver using an accelerator pedal, which is preferably equipped with a pedal travel sensor.
[0044] The driving track especially comprises a gear, which connects to the driving engine by way of a clutch or, in the case of an automatic transmission, by way of a torque converter. The clutch is operated by the vehicle driver using a clutch pedal, which is preferably likewise equipped with a pedal travel sensor. In addition, the gear, or an actuating means shifting the gears, is equipped with a sensor for detecting the gear engaged.
[0045] To determine the vehicle speed v, a wheel speed sensor is arranged on at least one wheel of the vehicle. Additional sensors of the motor vehicle can be used to e.g. find out whether the driver seat is occupied and whether the driver door is open or closed.
[0046] Several assist functions are provided in order to support the driver in handling the vehicle in the bottom speed range, preferably at vehicle speeds v lower than 4 km/h. In a favorable embodiment of the vehicle, the following assist functions are concerned which will be explained in detail hereinbelow:
A function for supporting the vehicle driver when stopping and starting to drive (Stop % Go, S&G), e.g. in a traffic jam. A dynamic brake function (Dynamic Brake Function, DBF) in which slowing down of the vehicle is assisted by means of the service brake by an additional intervention of the parking brake close to standstill. A function for the active vehicle hold (Active Vehicle Hold, AVH), which prevents the vehicle from unwanted roll away. A traffic jam assist system, which supports the driver likewise in stopping and starting to drive in a traffic jam. A function for the automatic release of the electric parking brake in a starting maneuver (Drive Away Release, DAR). A starting aid (Hill Start Assist, HAS) which prevents the vehicle from rolling rearwards in a starting maneuver.
[0053] It is arranged for by the invention that the existing assist functions or one or more control devices intended for this purpose check whether conditions for the activation or deactivation prevail. The activation of the functions takes place when a predefined vehicle state prevails, and/or when an actuating signal of an actuating means operated by the driver exists. The actuating means may e.g. relate to the brake actuating means, the driving engine control means, an activation switch of the electric parking brake, or a switch for the activation of the assist function.
[0054] The S&G function is used to slow the vehicle down by way of pressure buildup in the wheel brakes, when the vehicle driver releases the accelerator pedal, i.e. does not demand engine torque, at low vehicle speeds v, for example, when driving in a queue in traffic jams. Preferably, the brake pressure is reduced when a predefined vehicle speed v is reached, which is subsequently maintained.
[0055] Similarly, the SA function supports the driver by slowing the vehicle down until standstill by way of pressure buildup in the wheel brake when the desire of the driver to hold is recognized. This is preferably done in that it is detected at a low vehicle speed v that the driver no longer applies the accelerator pedal.
[0056] The S&G function as well as the SA function are activated and deactivated by the driver using a switch in an embodiment of the invention. However, it can also be provided in other embodiments of the invention that one of the two functions is automatically activated when the vehicle speed lies in a predetermined range during a predefined time span and that the S&G function is deactivated when a predefined vehicle speed is exceeded, or when standstill of the vehicle is detected.
[0057] The vehicle is stopped by the dynamic brake function (DBF) especially in an emergency stop situation. As this occurs, the vehicle is initially slowed down by means of the hydraulic service brake until a vehicle speed v of e.g. 4 km/h is reached. Automatic slowing down is ensured by means of the electric parking brake at lower speeds. The dynamic brake function is activated by means of a switch to be actuated by the vehicle driver and, thus, allows especially slowing down of the vehicle when the brake actuating means cannot be operated by the vehicle driver. The function is deactivated when standstill of the vehicle is detected.
[0058] The Active Vehicle Hold function secures the vehicle against unwanted rolling by building up brake pressure in the wheel brakes during standstill. The function is activated by the vehicle driver, preferably by means of a switch. Automatic activation is also feasible. If the driver leaves the vehicle, which is detected by means of a sensor at the driver's door preferably when the driver's door is opened, or if a predefined period has expired, there is preferably a switch-over from the hydraulic service brake to the electric parking brake. This function is preferably deactivated when the driver's desire to start to drive is detected, or when deactivation by the driver is carried out by means of the switch.
[0059] The Drive Away Release function is used in a starting maneuver to automatically release the electric parking brake of the vehicle that was activated during standstill. The electric parking brake is released in particular when a driver's desire to drive away is identified. The Drive Away Release function is then activated when standstill of the vehicle is detected and when the driver has activated the electric parking brake.
[0060] In a similar manner, the driver is supported during startup by the Hill Start Assist function because brake pressure is built up in the wheel brakes of the vehicle, which is being reduced or canceled when a desire to start is detected. The Hill Start Assist function either is activated by the vehicle driver, e.g. by means of a corresponding switch, or an automatic activation takes place when the driver applies the service brake and the vehicle is driving at a hill. Deactivation takes place preferably when the startup of the vehicle has been detected, or when a condition to terminate is satisfied. A termination condition may be e.g. an activation of the electric parking brake, or pulling of the handbrake, respectively. Besides, the function is favorably deactivated when it is not detected by means of a seat occupancy sensor at the driver's seat that the driver's seat is taken.
[0061] The Standstill Manager executes the control of the brake system, i.e. performing the assist functions, according to the invention. In a favorable embodiment of the invention, the Standstill Manager is designed as a state machine. The vehicle states, which are identified by the Standstill Manager, are illustrated in FIG. 1 and comprise the states of creeping, starting, holding, riding, and parking/securing. Besides, a state ‘switched off’ is provided in which the Standstill Manager is disabled.
[0062] The Standstill Manager is activated when the vehicle speed v falls under a predefined threshold value, e.g. 4 km/h. The Standstill Manager is deactivated for values of the vehicle speed v above the predetermined threshold value, i.e. it adopts the state ‘switched off’. Deactivation favorably also takes place when none of the vehicle's assist functions are activated. Besides, deactivation favorably also takes place when a defect is detected, for example, in the brake system or in vehicle sensors used by the Standstill Manager.
[0063] The detection of the other states appears from the conditions initiating a state transition of the Standstill Manager, which is also referred to as Transition. The possible Transitions are depicted in FIG. 2 .
[0064] Starting from the state ‘stop’, there are two possible Transitions. One Transition into the state ‘hold’ occurs when standstill of the vehicle is identified. Due to the usually limited resolution ability of the speed sensors or wheel rotational speed sensors used in vehicles, standstill is preferably identified in the practice when the vehicle speed v drops below a predetermined threshold value S v1 , for example 1 km/h. The Transition into the state ‘switched off’ occurs when none of the assist functions are activated or when the Standstill Manager is deactivated due to a defect.
[0065] Based on the state ‘hold’, there are three possible Transitions in a preferred embodiment of the invention. One Transition into the state ‘start-up’ occurs when a driver's desire to start driving is detected. In a favorable embodiment of the invention, this takes place e.g. when the accelerator pedal has been applied during a predefined time of e.g. roughly 100 ms or when the accelerator pedal has been applied at least by a predetermined pedal travel of e.g. 3% of the maximum pedal travel. The application of the accelerator pedal is determined by means of the pedal travel sensor at the accelerator pedal.
[0066] It may likewise be provided to check, instead of monitoring the accelerator pedal or in addition thereto, whether an engine torque prevails which is of a rate sufficient to allow start-up of the vehicle, and/or whether the clutch will be closed. As this occurs, the state of the clutch may be determined by means of a pedal travel sensor at the clutch pedal, and the control unit of the engine generally provides the value of the engine torque of the driving engine.
[0067] Further conditions for the Transition into the state ‘start-up’ are satisfied when a gear in the vehicle transmission is selected, what is found out using a sensor at the transmission or at the gearshift mechanism of the vehicle, and when the actuating means of the service brake is not actuated by the driver.
[0068] In another method that can be used herein, engagement of the clutch is detected when the driving torque lies in a predetermined range, i.e. especially is higher than a predetermined threshold value, and the rate of change of the engine rotational speed does not reach a predetermined threshold value. This method is advantageous in that for detecting the engagement of the clutch, or the start up, respectively, exclusively signals are used which are provided by the engine control, there being no need for additional sensors. In addition, likewise methods which can be used to detect start-up or engagement of the clutch are described in German publication DE 100 63 061 A1.
[0069] A transition from the state ‘hold’ to the state ‘park/secure’ preferably takes place when the period Δt st , in which the vehicle is at standstill, exceeds a predefined threshold value T st , and when the driver does not actuate the actuating means of the service brake. Further, the transition into the state ‘hold’ can occur when the driver leaves the vehicle, and leaving the vehicle, as described hereinabove, is detected by means of a sensor at the driver's door when the driver's door is opened.
[0070] A transition into the state ‘switched-off’ occurs due to the conditions, which have been described hereinabove.
[0071] Based on the state ‘start-up’, preferably three possible Transitions of the Standstill Manager are provided. If the starting maneuver is stopped, which is preferably detected by means of the accelerator pedal sensor because the driver releases or no longer applies the accelerator pedal, a transition into the state ‘hold’ occurs. A transition into the state ‘creep’ occurs when the vehicle speed v exceeds a threshold value which preferably corresponds to the threshold value S v .
[0072] Besides, a transition into the state ‘switched off’ can prevail when one of the conditions prevail, which have already been described in this regard.
[0073] Based on the state ‘creep’, there are favorably also three possible Transitions. In addition to the Transition into the state ‘switched off’, which occurs in the presence of the above-mentioned condition, especially a Transition into the state ‘stop’ is provided when a desire of the driver to stop is detected. This may e.g. be the case when the accelerator pedal sensor finds out that the driver has released the accelerator pedal completely.
[0074] Further, a transition into the state ‘hold’ takes place when the vehicle speed v drops below the threshold value S v . Based on the state ‘park/secure in position’, into which the Standstill Manager can pass from the state ‘hold’, there are three possible Transitions in a favorable embodiment of the invention. A Transition into the state ‘start-up’ occurs when the conditions are satisfied which also lead to a transition of the Standstill Manager from the state ‘hold’ into the state ‘start-up’. Further, a transition from the state ‘park’ into the state ‘hold’ can be provided which takes place when the driver actuates the actuating means of the service brake. In further embodiments of the invention, it may likewise be arranged that a Transition into the state ‘hold’ occurs, when a seat occupancy sensor finds out that the driver re-assumes his seat after an absence. Further, a transition into the state ‘switched off’ is provided when the conditions that have been described already prevail.
[0075] The Standstill Manager determines the activated assist functions in every state of the Standstill Manager, which corresponds to a corresponding state of the vehicle. The brake system is controlled by the Standstill Manager depending on the assist function or the assist functions that are activated.
[0076] In the state ‘stop’, both the traffic-jam assist function and the Dynamic Brake Function can be activated. As the traffic jam assist function causes a comfortable slowing down of the vehicle into standstill, and the Dynamic Brake Function shall bring about a quick slowing down of the vehicle in an emergency situation, the brake system is controlled by the Standstill Manager depending on the function that is activated in the respective state.
[0077] If the Dynamic Brake Function is activated, while the Standstill Manager adopts the state ‘stop’, pressure is built up in the hydraulic service brake, preferably with a high pressure increase gradient of e.g. 100 bar/s approximately. In a possible embodiment of the invention, the electric parking brake may be activated in addition. This shortens the stopping distance of the vehicle still further.
[0078] If the traffic-jam assist function is activated, while the Standstill Manager has adopted the state ‘stop’, pressure builds up in the hydraulic service brake with a low pressure-increase gradient of e.g. 30 bar/s approximately. This ensures a comfortable slowing down of the vehicle, avoiding in particular a pitching motion of the vehicle when stopped.
[0079] As likewise both of the above-mentioned assist functions can be activated, it is arranged to integrate a primary arbitration unit into the system, which detects which demand the Standstill Manager puts into practice, i.e. depending on which of the assist functions the brake system is controlled. It is preferably provided that the demands of the Dynamic Brake Function have priority over the demands of the traffic jam assist function so that a quick deceleration of the vehicle is safeguarded when the Dynamic Brake Function is active.
[0080] In the event of transition of the Standstill Manager into the state ‘hold’, initially a possibly prevailing pressure increase gradient is reduced until zero so that a pitching motion of the vehicle in the transition to standstill is avoided. Besides, the electric parking brake is released, if it had been activated in a previous state.
[0081] After the reduction of a possibly prevailing pressure increase gradient to zero and the release of the electric parking brake, it is provided in an embodiment of the invention to maintain the brake pressure prevailing in the service brake. This is done by closing the separating valves between the master brake cylinder and the wheel brake cylinders. Also, standstill of the vehicle is monitored using the measuring signals of the wheel speed sensors. If roll away of the vehicle is detected, the brake pressure in the service brake is increased by a predetermined amount by way of actuating the energy supply of the brake system.
[0082] In another embodiment of the invention, it may be arranged to reduce the brake pressure in the service brake in the state ‘hold’ until roll-away of the vehicle is detected, and to then increase the brake pressure by a predetermined amount. It is hereby prevented that excessive brake pressure prevails in the wheels brakes during standstill, which would impair the traction of the vehicle in a subsequent starting maneuver.
[0083] It may likewise be provided that the brake pressure adjusted in the state ‘hold’ by the Standstill Manager is calculated by way of the angle of longitudinal inclination of the vehicle, which is detected using an inclination angle sensor or a longitudinal acceleration sensor. The sensor measures the sum of the change of rate of the vehicle speed v and the downhill acceleration so that, with the change of rate of the vehicle speed v being known that can e.g. by determined by way of the measuring signals of the wheel speed sensors, the downhill acceleration and, based thereon, the angle of slope or the angle of longitudinal inclination of the vehicle can be determined. During standstill of the vehicle, especially
[0000] sin(α)=− a Sensor /g
[0000] applies, where α refers to the angle of longitudinal inclination of the vehicle, a Sensor refers to the signal of the longitudinal acceleration sensor, and g designates the acceleration due to gravity. The sign is chosen in such a fashion that a positive angle α is obtained, when the vehicle is placed in the uphill direction, while a negative angle α is obtained, when the vehicle is placed in the downhill direction.
[0084] When the Standstill Manager adopts the state ‘start-up’, while at least one of the available assist functions is activated, the brake pressure in the hydraulic service brake is reduced with a predetermined brake pressure gradient, and the electric parking brake, if activated, initially will be released in part and will be released completely thereafter.
[0085] It is arranged in a favorable embodiment of the invention that the Standstill Manager determines the brake pressure gradient for the brake pressure reduction depending on the angle of longitudinal inclination of the vehicle and the starting direction, which can be determined by way of the gear applied. Favorably, a higher brake pressure gradient is adjusted when starting to drive in downhill direction as compared to starting to drive in the plane.
[0086] When starting to drive in uphill direction, the brake pressure in the service brake in a favorable embodiment of the invention is reduced to the extent that the driving torque provided by the driving engine of the vehicle rises. As this occurs, the downhill force and the driving power that results from the engine torque provided by the driving engine are compared in a balance of forces. The brake pressure adjusted by the Standstill Manager is then calculated in such a fashion that the brake force compensates the difference between the downhill force and the driving power. If the driving power equals the downhill force or is higher than the latter, the brake pressure in the service brake will be reduced to zero.
[0087] After a Transition of the Standstill Manager into the state ‘park/secure’, the electric parking brake will be activated. The maximum brake torque of the electric parking brake is adjusted then so that standstill of the vehicle is safeguarded even if the grade changes during standstill, as can occur e.g. in Duplex garages.
[0088] The state ‘creep’ in which only the Stop & Go function can be active, is a passive state of the Standstill Manager, that means, brake force demands are not determined in this case. Hence, the state renders it possible also in the bottom speed range, in which the Standstill Manager is activated, that the driver controls the vehicle and especially the brake system independently, i.e. without the support of an assist system. The driver thus exclusively controls the brake force demands and the traction torque demands in the state ‘creep’.
[0089] The Standstill Manager examines in the state ‘switched off’ whether brake pressure prevails in the service brake of the vehicle. If this is the case, pressure is reduced with a predetermined brake pressure gradient. | The invention relates to a system for vehicle driver support, carrying out assist functions to support the driver for stopping and starting procedures, activated depending on a first comparison between at least one vehicle state parameter and a threshold value and/or based on first operating signals from an operating means operated by the driver. The system is characterised in that a control unit (SSM) determines at least one vehicle state by means of a further comparison of a vehicle state parameter with a given threshold value and/or by means of a further operating signals from the operating means, the control unit checks whether an assist function is activated and the control unit operates the brake system of the vehicle, depending on the determined vehicle state when at least one assist function is activated. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a lock, and more particularly, to a dual padlock, which may open by key or by code.
2. Description of the Related Art
Typically, conventional padlocks are classified into key lock, which may be opened by specific key, and combination lock, which may be opened by inputting specific code.
For the combination lock, if user forgot the code, he/she has to ask locksmith for help, or break the lock to open it. For the key lock, if user lost the key, he/she still has the same trouble to open it.
In addition, the Customs in airports usually ask passengers to have their luggage unlocked for a routine check. If passengers use the combination lock and forgot to open it, the Customs members will have trouble to open the luggage, sometime, they just break such luggage, and that cause dispute between passengers and Customs.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to provide a dual padlock, which may be opened by key or by inputting code.
The secondary objective of the present invention is to provide a dual padlock, with which the Customs members have no trouble to open it for a routine check.
The third objective of the present invention is to provide a dual padlock, with which user is easy to identify whether his/her luggage had been opened by the key of Customs members.
To achieve the foregoing objectives of the present invention, a dual padlock includes a housing, a shackle, a locking device, a locking spring, a transmission device, a code lock assembly, and a button member. The housing has a chamber inside, two top bores, a through bore, a button bore, and a plurality of dial bores. The shackle has a pivot end and a movable end inserted into the top bores of the housing respectively. The pivot end is formed with a head portion in the chamber, and the movable end has a slot. The locking device, which is received in the chamber of the housing, has a locking portion to be moved between a first position, in which the locking portion is engaged with the slot of the shackle, and a second position, in which the locking portion is disengaged with the slot of the shackle. The locking spring is received in the chamber of the housing and urges the locking device. The key lock assembly includes a key cylinder, which is received in the chamber of the housing and has an end received in the through bore, has a keyhole and a spiral slot. The transmission device has an end received in the spiral slot of the key cylinder of the key lock assembly and opposite end touching the locking device to be moved by the key cylinder. The code lock assembly is received in the chamber of the housing and has a shaft, a plurality of numeral wheels, which are fitted to the shaft and received in the dial bores respectively, and a return spring urging the shaft. The button member is pivoted on an interior side of the housing and has a first arm, which is received in the button bore of the housing and touches the shaft of the code lock assembly, and a second arm touching the locking device. Therefore, the dual padlock of the present invention may be opened by key and by input the right code.
In addition, the combination of the present invention may be provided with a first spring and a second spring urging the movable end the pivot end of the shackle to inject the shackle when the padlock is opened. It may be provided with a block urged by the first spring to prevent the locking device from affecting the action of the first spring.
The locking portion of the locking device may be provided with a sloping face to help the engagement of the locking device and the movable end of the shackle. The locking portion of the locking device may be provided with an arched gap to be engaged with the slot of the shackle firmly.
The dual padlock of the present invention further includes an indicator. The indicator is received in the chamber of the housing and is pivoted on the housing to be moved by the transmission device between a third position, in which the indicator is on a path of the transmission device, and a fourth position, in which the indicator is on a path of the button member. The housing is provided with a window that the indicator is visible through the window when the indicator is moved to the fourth position to identify whether the dual padlock of the present invention had been opened by key.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first preferred embodiment of the present invention;
FIG. 2 is an exploded view of the first preferred embodiment of the present invention;
FIG. 3 is a sectional view of the first preferred embodiment of the present invention, showing the inside structure of the padlock;
FIG. 4 is similar to in FIG. 3 , showing the pad lock been opened by code;
FIG. 5 is similar to in FIG. 3 , showing the pad lock been opened by key; and
FIG. 6 is a sectional view of a second preferred embodiment of the present invention, showing the inside structure of the padlock.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 to 5 , a dual padlock 10 constructed according to the first preferred embodiment of the present invention includes a housing 20 , a shackle 30 , a first spring 36 , a second spring 38 , a locking device 40 , a locking spring 45 , a key lock assembly 50 , a transmission device 56 , a code lock assembly 60 , a button member 70 , an indicator 76 and a third spring 78 .
The housing 20 is constructed by a front case 201 and a rear case 103 to form a chamber 21 therein. The housing 20 has two top bores 22 , a through bore 23 , a button bore 24 , three dial bores 25 and a window 26 . The top bores 22 , the through bore 23 , the button bore 24 , the dial bores 25 and the window 26 communicate the chamber 21 with outside.
The shackle 30 is a U-shaped bar having a pivot end 32 and a movable end 34 . The pivot end 32 is inserted into one of the top bores 22 of the housing 20 and has a head portion 321 received in the chamber 21 of the housing 20 . The movable end 34 is inserted into another top bore 22 of the housing 20 and has an annular slot 341 .
The first spring 36 is received in the chamber 21 of the housing 20 . A block 361 is urged by the first spring 36 to keep touching the movable end 34 of the shackle 32 .
The second spring 38 is received in the chamber 21 of the housing 20 to urge the pivot end 32 of the shackle 32 .
The locking device 40 , which is received in the chamber 21 of the housing 20 , has a locking portion 42 . The locking portion 42 includes an arched gap 421 , which is complementary to a bottom end of the annular slot 341 of the shackle 30 , and a sloping face 423 . The locking device 40 is moved between a first position, in which the locking portion 42 is engaged with the annular slot 341 of the shackle 30 ( FIG. 3 ), and a second position, in which the locking portion 42 is disengaged with the annular slot 341 of the shackle 30 ( FIG. 4 and FIG. 5 ).
The locking spring 45 is received in the chamber 21 of the housing 20 to urge the locking device 40 toward the first position.
The key lock assembly 50 includes a lock base 52 received in the chamber 21 of the housing 20 and a lock cylinder 54 received in the through bore 23 . The lock cylinder 54 has a keyhole 541 at an outer end thereof and a spiral slot 543 adjacent to an inner end thereof. A key (not shown) may be inserted into the keyhole 541 to turn the lock cylinder 54 . The key lock assembly 50 is a conventional device, so we do not describe the detail here.
The transmission device 56 has an end inserted into the slot 543 of the lock cylinder 54 and the other end touching the locking device 40 so that the transmission device 56 is moved by the lock cylinder 54 to move the locking device 40 to the second position from the first position.
The code lock assembly 60 , which is received in the chamber 21 of the housing 20 , has a shaft 62 , three numeral wheels 64 , three locking wheels 66 , a positioning spring piece 68 and a return spring 69 . The shaft 62 is formed with an extending wall 621 at an end thereof. The numeral wheels 64 are fitted to the shaft 62 and received in the dial bores 25 of the housing 20 respectively to be turned by user. The locking wheels 66 fitted to the shaft 62 and touch the numeral wheels 64 respectively. The return spring 69 is fitted to the shaft 62 and urges the extending wall 621 to urge the shaft 62 toward the button member 70 . When the numeral wheels 64 are turned to setting positions, the shaft 62 may be move freely, otherwise, the shaft 62 will be restricted by the locking wheels 66 . The code lock assembly 60 is a conventional device, so we do not describe the detail here.
The button member 70 has a hole 71 at a center thereof to be fitted to a shaft 205 on an interior side of the rear case 203 . The button member 70 further has a first arm 72 , which is inside the button bore 24 and touches the extending wall 621 of the shaft 62 of the code lock assembly 60 , and a second arm 74 , which touches the locking device 40 to move the locking device 40 to the second position from the first position. The second arm 74 is formed with a curved face 741 .
The indicator 76 is pivoted on the rear case 203 of the housing 20 and is received in chamber 21 to be swung between a third position, in which the indicator 76 is on a path of the transmission 56 ( FIG. 3 and FIG. 4 ), and a fourth position, in which the indicator 76 is on a path of the button member 70 . The indicator 76 is visible through the window 26 when it is moved to the fourth position, and is invisible when it is moved to the third position. The indicator 76 is formed with a sliding shaft 761 .
The third spring 78 is received in the chamber 21 of the housing 20 to urge the indicator 76 and an inner side of the housing 20 to move the indicator 76 approaching the window 26 of the chamber 21 as possible.
When the padlock 10 of the present invention is locked, as shown in FIG. 3 , the locking device 40 is at the first position to engage the locking portion 42 thereof with the annular slot 341 of the shackle 30 that the shackle 30 is secured. The first arm 72 of the button member 70 is restricted by the shaft 62 that the button member 70 can not swing in such condition. When user turns the numeral wheels 64 to the right code, the locking wheels 66 release the shaft 62 , and when the user presses the first arm 72 of the button member 70 , the second arm 74 of the button member 70 will move to the second position, as shown in FIG. 4 , that the first spring 36 and the second spring 38 will eject the shackle 30 to unlock the padlock 10 of the present invention.
To relock the padlock 10 of the present invention, user only has to press the shackle 30 to compress the first spring 36 and the second spring 38 that the locking device 40 will moved by the locking spring 45 to the first position. As a result, the padlock 10 of the present invention is locked.
When user inserts the key (not shown) into the keyhole 541 of the key lock assembly 50 and turns, the lock cylinder 54 is turned to move the locking device 40 , through the transmission device 56 , to second position from the first position, as shown in FIG. 5 , that the shackle 30 will be ejected to unlock the padlock 10 of the present invention. The padlock 10 of the present invention provides user choice to open it by key or by code that has much convenient to users. In addition, if user forgot to open the luggage with the padlock 10 of the present invention, the Customs member may open it by key for check procedure.
The indicator 76 is moved to the fourth position ( FIG. 5 ) from the third position ( FIG. 4 ) when the padlock 10 of the present invention is opened by key, and the indicator 76 will be left at the fourth position still when the padlock is relocked that user may identify whether his/her luggage had been opened by Customs member. When user presses the button member again, the second arm 74 of the button member 70 is turned clockwise to move the sliding shaft 761 of the indicator 76 along the curved face of the second arm 74 to return the indicator 76 to the third position.
There are many equivalent structures according the scope of the present invention. As shown in FIG. 6 , a dual padlock 80 of the second preferred embodiment of the present invention, which is similar to the first preferred embodiment, includes a housing 81 , a first spring 83 , a locking device 84 , a key lock assembly 85 , a transmission device 86 , a code lock assembly 87 , a button member 88 , an indicator 89 and a third spring 90 . A different part of the padlock 80 of the second preferred embodiment includes that a shackle 82 having a flexible cable 821 and two connecting device 823 , 825 , which act as the pivot end and movable end respectively. Another different part of the padlock 80 of the second preferred embodiment is that it has no second spring.
Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. | A dual padlock of the present invention includes a housing, a shackle, a locking device, a locking spring, a transmission device, a key lock assembly, a code lock assembly, and a button member. The shackle is openably provided on the housing. The locking device is received in the chamber of the housing and engaged with the shackle. The key lock assembly includes a key cylinder connected to the transmission device and the locking device. The button member is connected to a shaft of the code lock assembly and the lock device. Therefore, user may insert a key into the key lock assembly and turns to unlock the padlock. User also may input the right code to the code lock assembly that will unlock the pad lock too. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the sensitization of explosive compositions.
2. Description of the Prior Art
When a liquid explosive is to be transported on a truck or train or the like, it usually must be desensitized. That is, it usually must be treated in some manner whereby it is made safe for transportation. When a slurried explosive is to be transported on a truck or train or the like it must be in a desensitized condition wherein the sensitizers have not yet been added. Inadvertent explosions are highly undesirable to say the least.
On the other hand, when such an explosive, whether it be liquid or slurried, is to be detonated it is undesirable to have it desensitized. At this time, easy detonation is desirable--not undesirable.
It is common practice to obtain a desensitizing agent, mix it with or dissolve it in a liquid explosive when the explosive is to be transported and then separate it from the explosive just before the explosive is to be detonated. For example, alcohol is commonly mixed with nitroglycerine for desensitization purposes and then removed just prior to use of the nitroglycerine in propellant processing. Slurried explosives are mixed at the point of usage in order to add the sensitizers. For example a large tank truck of slurried explosive ingredients will be pumped into a blasting hole via a pump track wherein the sensitizer ingredients are metered into the flow line. These practices are cumbersome and time-consuming. It would be desirable to avoid the necessity for the practices altogether but, unfortunately, no one has yet devised a way whereby the use of desensitizing agents in conjection with highly sensitive liquids can be avoided if the liquids are to be transported and, additionally, the on sight sensitization of slurried explosives goes on. Accordingly, the next best thing would be to avoid the necessity for removing desensitizing agents from liquid explosives and, additionally, it would be advantageous to provide a simple means for sensitizing liquids which are explosive but are naturally hard to detonate, i.e., liquids which need no desensitizing agents and to provide a similar means for sensitizing slurried explosives. (Note that, according to this invention, liquids which require no desensitizing agents are equated with slurried explosives which also need no desensitizing agents.
SUMMARY OF THE INVENTION
According to this invention, the necessity for removing a desensitizing agent from a liquid explosive prior to detonation of the explosive is removed by dispersing bubbles of a high gamma gas in the explosive just prior to detonation. The high gamma gas sensitizes the explosive and overcomes the effect of any desensitizing agent present. Such a gas may also be used to sensitize liquid explosives which contain no desensitizing agent, i.e., liquids which lack sensitivity and further, may be used to sensitize slurried explosives.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The mechanical aspect of this invention may be practiced by utilizing any known technique for dispersing a gaseous material into a liquid at a desirable time. That is, those skilled in the mechanical arts will be quite capable of providing a gas containing a high gamma gas, providing the container with proper tubing leading from it into a manifolded container containing a liquid or slurried explosive to be sensitized and providing for the metering of gas into the explosive in a desirable amount at a desirable time. Therefore, no great detail is needed to enable one skilled in the art to practice the mechanical aspect of the invention.
As indicated above, a high gamma gas is used as the sensitizing material. The term gamma as used herein means the ratio of specific heat at constant pressure (Cp) to specific heat at constant volume (Cv). The term high means 1.6 or greater. Among gases which have gammas of 1.6 or greater are such well known gases as argon, krypton and helium.
To practice this invention, bubbles of high gamma gas are dispersed in the explosive, preferably just prior to use. This is true whether the explosive is a desensitized liquid, a non-desenitized liquid or a slurry.
High gamma gas bubbles will further sensitize an already highly sensitive liquid such as n-propyl nitrate. Additionally, high gamma gas will sensitize a mixture or solution of n-propyl nitrate and a desensitizing agent by overcoming the effect of the desensitizing agent.
High gamma gas will overcome the desensitizing effect of alcohol in nitroglycerine. It will also sensitize nitroglycerine. It will also sensitize nitroglycerine which contains no desensitizing agent.
High gamma gas will sensitize a slurry such as a slurry of ammonium nitrate, water and aluminum powder and other similar slurried explosives.
High gamma will sensitize a relatively insensitive composition such as a hydrazine-hydrazine nitrate composition. And, of course, it will sensitize hydrazine which is highly sensitive.
To be most effective, it is preferred that at least 1 volume percent of the composition be high gamma gas bubbles when the composition is ready for detonation. Up to 5 volume percent or more may be high gamma gas bubbles.
It is theorized that, when the gas in the bubbles is acted on by pressure produced by an initiator, the gas temperature is greatly increased and the hot gas decomposes surrounding liquid assisting the explosion to occur. The gas in any given gas bubble will not, of course, be entirely high gamma gas. It is practically impossible to keep gases such as oxygen and nitrogen from being present in liquids and such gases will naturally make up a portion of any bubble formed in the liquid. However, it is not necessary that the bubbles contain only high gamma gas. Bubbles need only contain a substantially large amount of suitable gas. | Bubbles of high gamma gas are incorporated into the liquid component of a quid or slurried explosive to sensitize the explosive. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a gel sheet used for cosmetics, pharmaceuticals and the other applications, particularly to a cosmetic sheet or percutaneous absorption preparation to be applied to the skin.
[0003] 2. Description of the Related Art
[0004] Gel sheets mainly comprising agar or the like are conventionally known. Since the agar as a gel forming component forms a network structure in water, such gel sheets can be used for the purpose of moisture retention. The gel sheets made of agar however do not have a sufficient strength and in addition, there is a difficulty in incorporating an oily pharmaceutically active ingredient therein.
[0005] Gel sheets using an acrylic polymer gel are, on the other hand, not free from the fear of toxicity of the residual monomer and those with less irritation to the skin are requested. Many gel sheets need a crosslinking agent, the use of which complicates their preparation process. It is also impossible to incorporate a pharmaceutically active oily ingredient in such gels freely.
[0006] Many of cosmetic sheets to be applied to the skin such as face or hands contain therein a moisturizing agent and a polymer for supporting the moisturizing agent therewith, or are used after applying components containing a moisturizing agent to the sheet. For example, a cosmetic moisturizing sheet containing a moisturizing agent such as hyaluronic acid or collagen supported on a fiber sheet is disclosed in Japanese Patent Application Unexamined Publication No. 9-238738/1997. A cosmetic pack comprising chitosan and a medium paste, and a collagen-free moisturizing mask obtained by crosslinking a cationic biopolymer are disclosed in Japanese Patent Unexamined Application Nos. 6-48917/1994 and 2001-502678, respectively.
[0007] The above-described gel sheet is typically a paper sheet impregnated with a moisturizing agent. It does not have a sufficient water retention capacity and in addition, the paper sheet causes a sense of discomfort upon use. Gel polymers have improved adhesion to the skin, but are not sufficient. Another drawback of them is a complicated preparation process owing to the use of a crosslinking agent.
[0008] As a countermeasure against the above-described problems, a gel sheet of cellulose ether having a low molar substitution is disclosed in Japanese Patent Application Unexamined Publication No. 6-48197/1994. The gel sheet is free from the problem of a monomer which occurs upon use of an acrylic polymer, can be prepared without extra effort because a crosslinking agent is not necessary. The gel sheet has a sufficient water retaining capacity, and does not cause any sense of discomfort upon use. When such a sheet is applied to the body, however, it peels off the body before a drug such as a moisturizing agent, an anti-wrinkle agent, an anti-spot agent or a whitening cosmetic with which the sheet has been impregnated starts exhibition of its effect (about 20 minutes). It cannot keep its adhesion for at least 60 minutes, time at least necessary for the effective delivery of the chemical substance. Thus, the gel sheet has a drawback in skin adhesion. The above-described hydrous sheet of low-substituted cellulose ether can be prepared by casting an alkaline solution of low-substituted cellulose ether onto a supporting plate, neutralizing and coagulating the sheet with an acid and then washing off, from the sheet, the salt formed by neutralization. In order to produce a sheet containing a pharmaceutically active ingredient, the pharmaceutically active ingredient is added in advance upon preparation of an alkaline solution, or a sheet formed is dipped in a solution containing the pharmaceutically active ingredient. However, depending on a type of pharmaceutically active ingredient, production of sheet containing the pharmaceutically active ingredient has problems, for example, that the ingredient is decomposed in the alkaline solution, it does not dissolve in the solution smoothly, or a sufficient amount of the ingredient cannot be supported in the sheet even if the sheet is dipped in an aqueous solution of the ingredient. Moreover, an oily substance immiscible with water cannot be incorporated.
[0009] There is a process of preparing a hydrous gel sheet having improved skin adhesion, which comprises casting, on a supporting plate, a mixture of an alkaline solution of low-substituted cellulose ether and water-soluble and alkali-soluble cellulose ether having a substitution degree of 1.1 to 1.4, neutralizing and coagulating a sheet of the mixture on the plate with an acid, and washing off the salt in the sheet. By this process, however, it is impossible to prepare a hydrous sheet having a high content of water-soluble cellulose ether because a portion of the water-soluble cellulose ether leaks out during the washing step for removing the neutralization salt, leading to a reduction in the strength of the hydrous sheet. The higher the content of the water-soluble cellulose ether is, the better the skin adhesion of the sheet is. The sheet obtained by the above-described method therefore does not have sufficient skin adhesion.
[0010] As percutaneous absorption preparations, a nicotine-containing film preparation is disclosed in Japanese Patent Application Unexamined Publication No. 2003-95947. A skin adhesive film preparation obtained by incorporating a water-soluble cellulose lower-alkyl ether in a fibroblast growth factor is disclosed in Japanese Patent Application Unexamined Publication No. 7-82171/1995. A membrane-attached adhesive multilayer film preparation comprising a water-soluble polymer layer containing a drug and an adhesive layer containing an adhesive substance is disclosed in Japanese Patent Application Unexamined Publication No. 9-235220/1997. Any of them does not relate to a hydrous sheet containing low-substituted cellulose ether.
SUMMARY OF THE INVENTION
[0011] With the foregoing in view, the present invention has been completed. An object of the present invention is to provide a hydrous gel sheet comprising a polymer harmless to the living body and being highly adhesive to the skin. Another object of the invention is to provide a hydrous gel sheet comprising a pharmaceutically-active oily ingredient and being highly adhesive to the skin.
[0012] The present inventors have carried out an extensive investigation with a view to attaining the above-described objects. As a result, it has been found that a film preparation containing a desired amount of drug can be prepared by casting a mixture onto a supporting plate wherein the mixture comprises a drug, wetly shear-triturated low-substituted cellulose ether having a molar substitution of 0.05 to 1.0 per anhydrous glucose unit (C 6 H 10 O 5 ) and an aqueous solution of water-soluble cellulose ether; and then drying the cast mixture. A hydrous gel sheet having excellent skin adhesion can be prepared only by wetting the film preparation when it is used, leading to the completion of the invention.
[0013] In one aspect of the present invention, there are thus provided a film preparation comprising a drug, wetly shear-triturated low-substituted cellulose ether having a molar substitution of 0.05 to 1.0 per anhydrous glucose unit and water-soluble cellulose ether and being capable of adhering to the skin for 100 minutes or greater; and a skin-adhesive hydrous sheet obtained by wetting said film preparation.
[0014] In another aspect of the present invention, there is also provided a preparation method of a film preparation, which comprises casting a mixture onto a supporting plate wherein the mixture comprises a drug, wetly shear-triturated low-substituted cellulose ether having a molar substitution of from 0.05 to 1.0 per anhydrous glucose unit and an aqueous solution of water-soluble cellulose ether; and then drying the cast mixture.
[0015] According to the present invention, a film preparation containing a desired amount of a drug is excellent in water retention. When the preparation is wetted with water, it has excellent sheet strength and elasticity. It is excellent in skin adhesion and feeling upon use. A skin adhesive hydrous sheet containing an oily substance can also be obtained according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The present invention will hereinafter be described in details.
[0017] Low-substituted cellulose ether to be used in the present invention is insoluble in water but soluble in an alkaline solution. Cellulose is generally insoluble in water. However, when the hydrogen atom of the hydroxyl group on the glucose ring of the cellulose is substituted with an alkyl or hydroxyalkyl group, the cellulose becomes water-soluble, though depending on the degree of its substitution. When the substitution degree is low, the cellulose is not water-soluble and instead, tends to become soluble in an alkaline solution. In many cases, when low-substituted cellulose ether powder is dispersed in water, it becomes partially swelled with water. When it has a high molar substitution, it becomes water-soluble and loses alkaline solubility.
[0018] Low-substituted cellulose ether to be used in the present invention, which is insoluble in water but soluble in an alkali, preferably has a molar substitution of from 0.05 to 1.0. Examples of various low-substituted cellulose ethers (the number in parentheses means a molar substitution degree) may include low-substituted methyl cellulose having 3 to 15 wt % of a methoxyl group (from 0.16 to 0.85), low-substituted hydroxyethyl cellulose having 3 to 15 wt % of a hydroxyethoxyl group (from 0.08 to 0.45), low-substituted hydroxypropyl cellulose having 4 to 20 wt % of a hydroxypropoxyl group (from 0.09 to 0.51) and low-substituted hydroxypropyl methyl cellulose having 3 to 12 wt % of a methoxyl group and 4 to 20 wt % of a hydroxypropoxyl group (from 0.25 to 1.0 in total of both substituents). The substitution degree of a cellulose ether can be measured in accordance with the Japanese Pharmacopoeia.
[0019] Such low-substituted cellulose ether is insoluble in water but soluble in an aqueous alkaline solution. It absorbs water and swells. The typical example thereof may include low-substituted hydroxypropyl cellulose, which is commercially available now from Shin-Etsu Chemical Co., Ltd., under the trade name of “L-HPC”. It is listed in the Japanese Pharmacopoeia and popularly used as a disintegrant to be incorporated in tablets, particularly in the field of pharmaceutical materials.
[0020] A preparation process of such low-substituted cellulose ether is known. For example, as described in Japanese Patent Application Unexamined Publication No. 57-53100/1982, alkali cellulose has to be prepared first. It may be obtained by immersing a starting pulp sheet in an aqueous alkaline solution such as sodium hydroxide; or mixing pulverized pulp directly with an alkaline solution; or adding an alkali to a pulp powder dispersed in an organic solvent. The alkali cellulose thus obtained is placed in a reactor, followed by the addition of an etherifying agent such as propylene oxide or ethylene oxide. The reaction mixture is then heated for the reaction to produce the cellulose ether. After completion of the reaction, the resulting crude cellulose ether is transferred into another tank, where the alkali is neutralized with an acid. The solid thus obtained is washed, dried and then pulverized to produce a powder as a final product. Alternatively, the final product may be prepared by completely or partially dissolving in water the crude cellulose ether just after the reaction, neutralizing the resulting solution, collecting the precipitated polymer, and washing, drying and pulverizing the polymer.
[0021] According to the method for producing a film preparation, the film preparation is produced by casting a mixture onto a supporting plate wherein the mixture comprises a drug, wetly shear-triturated low-substituted cellulose ether having a molar substitution of 0.05 to 1.0 per anhydrous glucose unit, and an aqueous solution of water-soluble cellulose ether; and drying the cast mixture. The wetly shear-triturated low-substituted cellulose ether can be obtained by shear-triturating an aqueous dispersion of low-substituted cellulose ether with a wet-type pulverizer.
[0022] The aqueous dispersion of low-substituted cellulose ether can be prepared without any special agitator simply by placing the low-substituted cellulose ether in water, or by adding water to the low-substituted cellulose ether for absorption and expansion. The low-substituted cellulose ether can be shear-triturated directly by placing the low-substituted cellulose ether and water in a wet-type pulverizer.
[0023] Examples of the wet-type pulverizer may include a vibratory ball mill, a colloid mill, a homomixer, a propeller-type homogenizer, a high-pressure homogenizer, a ultrasonic homogenizer and a wet-type pulverizer of stone-mortar form. The high-pressure homogenizer (e.g. “Ultimaizer”, product of Sugino Machine Limited; “Nano-mizer”, product of Yoshida Kikai Co., Ltd.; “Microfluidizer”, product of Mizuho Industrial Co., Ltd.) are advantageous for obtaining a uniformly shear-triturated product. The pressure for the treatment may be variable depending on a substance to be treated. The pressure may be preferably from 100 to 250 MPa. When the pressure is less than 100 MPa, the satisfactory aqueous dispersion may not be obtained. When the pressure is more than 250 MPa, it may not be suited from the mechanical viewpoint.
[0024] According to Japanese Patent Application Unexamined Publication No. 2002-204951, there is a method for obtaining a uniformly shear-triturated product from an aqueous dispersion of low-substituted cellulose ether, the method comprising a step of adding an acid to an alkaline solution of low-substituted cellulose ether for neutralization and precipitation, while mixing the solution with a high speed stirrer. There is also a modified method comprising steps of adding an acid to an alkaline solution of low-substituted cellulose ether to form a gel product as a result of neutralization and precipitation, washing the gel product with hot water and then carrying out wet shear-trituration.
[0025] As the preparation of the alkaline solution of low-substituted hydroxylpropyl cellulose, a low-substituted cellulose ether powder as a final product may be dissolved in an aqueous alkaline solution. This method can bring the same result as the method for dissolving in water an alkali-containing crude cellulose ether just after the reaction. In the latter case, the crude cellulose ether contains an alkali so that only water may be added, but an alkali may be added so as to ensure complete dissolution. Both methods are applicable to the present invention.
[0026] Examples of the alkali for dissolving the cellulose ether may include potassium hydroxide and sodium hydroxide. The concentration of alkali may vary depending on the kind or substitution degree of the substituent for the cellulose ether so that it may be determined accordingly. The alkali concentration may be preferably 2 to 25 wt %, particularly preferably 5 to 12 wt %. As a typical example, an aqueous 10 wt % sodium hydroxide solution can be used for low-substituted hydroxypropyl cellulose having a molar substitution of 0.2. The solution having the low-substituted hydroxypropyl cellulose dissolved may be transparent or may not be completely transparent, depending on the difference in the substituent distribution for the hydroxypropyl cellulose. Even if the solution is not completely transparent, it is regarded as a solution when the viscosity shows an apparent rise.
[0027] Examples of the acid used for neutralization may include organic acid such as acetic acid, formic acid and propionic acid; and inorganic acid such as hydrochloric acid and sulfuric acid. The acid concentration can be selected freely. The preferable acid concentration may be about 5 to 10 wt %.
[0028] The concentration of low-substituted cellulose ether which will be subjected to shear-trituration may be preferably from 2 to 20 wt %. When the concentration is less than 2 wt %, the burden for drying may become high. The shear-trituration treatment makes the slurry in the form of gel or sol thicken so that the concentration exceeding 20 wt % may disturb the treatment.
[0029] The average particle size of the shear-triturated low-substituted cellulose ether being in the swelling state containing water may be preferably 20 μm or less on basis of the volume as measured by the laser diffraction scattering method. It is known that the particle size of water-insoluble polymer in water has an influence on the film forming property after drying. This also applies to the shear-triturated low-substituted cellulose ether. As the particle size of the shear-triturated low-substituted cellulose ether is smaller, the particles will be packed most closely when the aqueous dispersion thereof is dried. The adjacent particles will coalesce each other, facilitating the formation of a transparent continuous film. The resulting continuous transparent film has high strength in a dry state, and becomes a gel sheet by absorbing water while maintaining its shape. Thus, a skin adhesive hydrous sheet can be obtained. On the other hand, when the average particle size exceeds 20 μm, only a partially-transparent discontinuous film or a sediment of powder can be obtained by drying the aqueous dispersion. The sediment of powder has low strength in the dry state and cannot keep its shape when wetted with water, thus making it impossible to prepare an intended skin-adhesive hydrous sheet. Although no particular limitation is imposed on the lower limit of the particle size, it may be preferably about 1 μm.
[0030] Examples of the water-soluble cellulose ether (the numeral in parentheses means a molar substitution) may include alkyl cellulose such as methyl cellulose (a methoxyl group: 1.5 to 2.0), hydroxyalkyl celluloses such as hydroxyethyl cellulose (a hydroxyethyl group: 1.0 to 3.0) and hydroxypropyl cellulose (a hydroxypropyl group: 2.0 to 3.0), hydroxyalkylalkyl celluloses such as hydroxypropylmethyl cellulose (a methoxyl group: 1.1 to 2.0, hydroxypropyl group: 0.1 to 0.4), hydroxyethylmethyl cellulose (a methoxyl group: 1.1 to 2.0, a hydroxyethyl group: 0.1 to 0.4), and carboxymethyl cellulose (carboxymethyl group: 0.5 to 2.5). Hydroxypropylmethyl cellulose may be suited for producing a film preparation containing an oily substance because it has low surface tension and high surface activity and can form a uniform emulsion containing small droplets of oily substance.
[0031] The viscosity of the 2 wt % aqueous solution of water-soluble cellulose ether at 20° C. may be preferably from 3 to 4000 mPa·s, especially preferably from 3 to 100 mPa·s. When the viscosity is less than 3 mPa·s, the strength of the obtained film or adhesion to the skin thereof may lower. When the viscosity is more than 4000 mPa·s, the formation of a high concentration solution is difficult so that drying time may prolong or defoaming of the solution may become difficult.
[0032] A preparation method for producing the water-soluble cellulose ether is described, for example, in Japanese Patent Application Unexamined Publication No. 10-158302/1998. Alkali cellulose has to be produced first. The alkali cellulose may be produced by immersing a starting pulp sheet, in an aqueous alkaline solution such as sodium hydroxide; or by mixing the pulverized pulp directly with an alkaline solution; or adding an alkali to a pulp powder dispersed in an organic solvent. The alkali cellulose thus obtained may be placed in a reactor, followed by the addition of an etherifying agent such as propylene oxide or ethylene oxide. The mixture may heated for the reaction so that cellulose ether is produced. After completion of the reaction, the resulting crude cellulose ether is transferred into another tank. When the cellulose ether is sparingly soluble in hot water such as methyl cellulose, it is subjected to necessary neutralization and washing with hot water. When the cellulose ether is soluble in both hot water and cool water such as carboxymethyl cellulose, it is subjected to necessary neutralization, followed by washing with a poor solvent such as methanol-containing water. Then, is dried and pulverized to obtain a final power product.
[0033] According to the method for producing a film preparation of the present invention, water-soluble cellulose ether may be preferably mixed with an aqueous solution of water-soluble shear-triturated low-substituted cellulose ether and a drug. The concentration of the water-soluble cellulose ether in an aqueous solution can be selected in consideration of the mixing ratio of the low-substituted cellulose ether to water-soluble cellulose ether, or concentration for the casting.
[0034] The weight ratio of the low-substituted cellulose ether to the water-soluble cellulose ether for the film preparation of the invention may be preferably from 98/2 to 40/60, more preferably from 95/5 to 50/50. When the ratio is more than 98/2, the film adhered to the skin may peel off before the drug such as a moisturizing agent, an anti-wrinkle agent, an anti-spot agent or a whitening cosmetic starts its action (where the action starts in about 20 minutes). It may be impossible to keep the adhesion for 60 minutes or greater which is at least necessary for the drug to act on the skin. A film containing an oily substance may be prepared by mixing the water-soluble cellulose ether and the oily substance to form an emulsion, and forming the emulsion into the film which supports them uniformly. When the ratio of the low-substituted cellulose ether to water-soluble cellulose ether is larger than 98/2, it may not bring about a sufficient effect and a stable emulsion may not be prepared easily. In this case, the film thus obtained may be uneven.
[0035] When the ratio of the low-substituted cellulose ether to the water-soluble cellulose ether is less than 40/60, the film strength after wetting may become weak. After peeling, a portion of the film may remain on the skin so that discomfort may be generated for use of the hydrous sheet.
[0036] Although no particular limitation is imposed on the drug to be used in the invention, the present invention is especially effective for the use of an oily substance immiscible with water.
[0037] Examples of the drug to be used in the invention may include an anti-wrinkle agent such as retinol; an anti-spot agent such as cysteine; a whitening cosmetics; a moisturizing ingredient such as glycerin, hyaluronic acid, collagen, squalene, docosahexaenoic acid, eicosapentaenoic acid, saccharides, amino acid, placenta extract, sorbitol and polyethylene glycol; a softener such as olive oil, cetyl alcohol, lanolin and stearyl alcohol; a blood circulation promoter such as tocopherol, an anti-inflammatory such as glycyrrhizinic acid; and a skin beautifying agent such as various Vitamin Cs. A pharmaceutical sheet comprising at least one of these ingredients is preferred. If necessary, a water-soluble organic solvent such as alcohol may be added. In use for a percutaneous absorption preparation, examples of the local anesthetic may include tetracaine, diethylaminoethyl parabutylaminobenzoate, oxybuprocaine, lidocaine, dibucaine and propitocaine. Examples of the analgesic antiphlogistic may include aspirin, acetaminophen, ethenzamide, ibuprofen, indomethacin, ketoprofen, glycyrrhizinic acid, flufenamic acid, phenylbutazone, naproxen, oxyphenbutazone, dicrofenac sodium, benzidamine, mepirizole, isothipendyl hydrochloride, bufexamac, bendazac, azulene, piroxicam and diflunisal. Examples of the anti-inflammatory steroid may include triamcinolone acetonide, dexametazone, hydrocortisone acetate, fluocinolone acetonide, prednisolone and betamethasone valerate. Examples of the antibiotic may include penicillin, gentamicin, cefalexin, erythromycin, chloramphenicol and tetracycline. Of these, an oily substance which is liquid at ordinary temperature and is immiscible with water may especially preferable, including retinol, squalane, docosahexaenoic acid, eicosapentaenoic acid, olive oil and tocopherol.
[0038] Although the content of the drug is variable depending on its kind, 50 wt % or less in the film preparation may be preferable. When the content is more than 50 wt %, the sheet strength after wetting may lower so that the sheet may remain on the skin as it is peeled off the skin. The conventionally used hydrous sheet which comprises acrylic polymer or agar can hold only several wt % of an oily substance. However, the film of the present invention can advantageously hold about 30 to 40 wt % of the oily substance. It presumably owes to that the low-substituted cellulose ether can retain not only water but also an oily substance and is highly effective for suppressing bleeding.
[0039] The film preparation of the invention can be produced by casting a mixture onto a supporting plate wherein the mixture comprises a drug, wetly shear-triturated low-substituted cellulose ether and an aqueous solution of water-soluble cellulose ether and then drying the cast mixture.
[0040] The concentration of the mixture to be used for casting is not particularly limited and can be controlled depending on the application purpose. The concentration of the mixture as solid concentration may be, for example, from 2 to 30 wt %.
[0041] The casting method of the mixture is not particularly limited and a conventional method can be employed. The material of the supporting plate is not particularly limited and may include glass and Teflon (trade mark). For example, the mixture is cast onto a glass plate with a casting blade to give a proper thickness. The thickness is not particularly limited and can be adjusted depending on the application purpose. The thickness may be preferably between 0.1 mm and 10 mm.
[0042] The temperature for drying the film is not particularly limited and may be preferably from 60 to 80° C. The film may be dried preferably until the water content therein becomes about 10 wt % or less. When the drying is insufficient, film formation may be incomplete so that the sheet strength after wetting may lower. The removal of water in the film can improve storage stability of the drug susceptible to water.
[0043] The dried film preparation can be used as a sheet having a high water content after wetted with water upon use. The amount of water added for wetting may be selected depending on the application purpose. The film which has absorbed water completely may be preferable. According to the present invention, the water content of the film may be preferably 90 wt % after absorption of water.
[0044] As the skin adhesion test, the film is punched out to obtain circular film having a diameter of 2.5 cm as a sample for evaluation. A small amount of water is applied to the circular film to allow it to absorb water therein. The film is applied to the back of the hand and time until the hydrous sheet naturally peels off the hand is measured.
[0045] The adhesion time of the sheet to the skin is 100 minutes or greater. Although no upper limit is imposed, it is presumed to be about 400 minutes.
[0046] The drug such as a moisturizing agent, an anti-wrinkle agent, an anti-spot agent or a whitening cosmetic with which the sheet is immersed may start its action in about 20 minutes. The minimum time required for the drug to bring its effect may be 60 minutes or greater. The time required for the drug to bring its effect to the full extent may is 100 minutes or greater. The drug such as a moisturizing agent, an anti-wrinkle agent, an anti-spot agent or a whitening cosmetic may not bring its effect when the adhesion time is not greater than 60 minutes, and may not bring its effect completely when the time is not greater than 100 minutes.
[0047] The present invention will hereinafter be described by Examples. However, it should not be construed that the present invention is limited to or by these Examples.
EXAMPLE 1
[0000] <Preparation of Wetly Shear-Triturated Low-Substituted Cellulose Ether>
[0048] A twin-shaft kneader having an internal volume of 5 L was filled with 2360 g of pure water of 25° C. In the kneader, 150 g of low-substituted hydroxypropyl cellulose powder (product of Shin-Etsu Chemical Co., Ltd., molar substitution degree of 0.25) was added and dispersed uniformly. A 49 wt % aqueous NaOH solution (490 g) of 25° C. was added thereto so as to obtain an aqueous NaOH solution of the low-substituted hydroxypropyl cellulose (concentration of the low-substituted hydroxypropyl cellulose: 5 wt %; NaOH concentration: 8 wt %).
[0049] The resulting solution was neutralized with 378 g of glacial acetic acid so that a gel-like precipitate was obtained. Hot water was added in an amount of 20 times the weight of the low-substituted hydroxypropyl cellulose to form slurry. The slurry was dehydrated by a centrifugal dehydrator. This operation was repeated again to obtain a washed product of low-substituted hydroxypropyl cellulose.
[0050] Pure water was added to the resulting washed product so that a solid concentration reaches 4 wt %, whereby a raw material for wet shear-trituration was obtained. The raw material was wetly shear-triturated with a pulverizer of stone-mortar type (“Cerendipitor MKCA6-3INV”, product of Masuko Sangyo Co., Ltd.) under the following conditions:
clearance between the upper and lower grinders: 60 micron, rotation speed: 1500 rpm (peripheral speed: 11.7 m/sec) and treating speed: 1.0 kg/min.
[0052] This operation was repeated 5 times to yield wetly shear-triturated low-substituted hydroxypropyl cellulose. The slurry was thickened and became creamy. The measurement of an average particle size with a laser scattering particle size distribution analyzer “HORIBA LA-90” (product of Horiba, Ltd.) showed an average particle size of 10 μm.
[0000] <Preparation of Film>
[0053] The 87.5 g (solid content: 3.5 g) of 4 wt % slurry containing the wetly shear-triturated low-substituted hydroxypropyl cellulose and 15 g (solid content: 1.5 g) of a 10 wt % aqueous solution of hydroxypropylmethyl cellulose (product of Shin-Etsu Chemical Co., Ltd.; molar substitution degree of the methoxyl group: 1.87; that of the hydroxyproxyl group: 0.23; the viscosity of a 2 wt % aqueous solution at 20° C.: 6 mPa·s) were mixed with stirring at 300 rpm. To the resulting mixture, 1.07 g of α-tocopherol and 1.07 g of ascorbic acid were added and then mixed with stirring at 300 rpm, whereby a uniform creamy emulsion was obtained.
[0054] The emulsion was cast onto a glass plate so as to form a film having a thickness of 1.5 mm. The film was dried in a blast oven at 60° C., whereby a transparent continuous film having a thickness of 70 μm and the below-described composition was obtained.
Low-substituted cellulose ether/water-soluble cellulose ether: 7/3 (weight ratio) Low-substituted hydroxypropyl cellulose: 46.4 wt % Hydroxypropylmethyl cellulose: 19.9 wt % α-Tocopherol: 14.2 wt % Ascorbic acid: 14.2 wt % Water: 5.3 wt %
[0061] The film was punched out into a circular film of 2.5 cm in diameter and was used as a sample for evaluation.
[0062] A hydrous sheet obtained by applying a small amount of water to the circular film and allowing it to absorb water therein was attached to the back of the hand. The period of time until the peeling of the film starts, feeling upon use, and the state after the film was peeled off were tested and results are shown in Table 1.
EXAMPLE 2
[0063] The 75.0 g (solid content: 3.0 g) of 4 wt % slurry containing the wetly shear-triturated low-substituted hydroxypropyl cellulose which had been prepared in the same manner as in Example 1 and 20.0 g (solid content: 2.0 g) of a 10 wt % aqueous solution of hydroxypropyl cellulose (product of Shin-Etsu Chemical Co., Ltd.; molar substitution degree of the hydroxypropoxyl group: 2.5; the viscosity of a 2 wt % aqueous solution at 20° C.: 6 mPa·s) were mixed with stirring at 300 rpm. To the resulting mixture, 1.07 g of α-tocopherol and 1.07 g of ascorbic acid were added and then mixed with stirring at 300 rpm, whereby a uniform creamy emulsion was obtained.
[0064] The emulsion was cast onto a glass plate so as to form a film having a thickness of 1.0 mm. The film was dried in a blast oven at 60° C., whereby a transparent continuous film having a thickness of 60 μm and the below-described composition was obtained.
Low-substituted cellulose ether/water-soluble cellulose ether: 6/4 (weight ratio) Low-substituted hydroxypropyl cellulose: 40.0 wt % Hydroxypropyl cellulose: 26.6 wt % α-Tocopherol: 14.2 wt % Ascorbic acid: 14.2 wt % Water: 5.0 wt %
[0071] The film was punched out into a circular film of 2.5 cm in diameter and was used as a sample for evaluation.
[0072] A hydrous sheet obtained by applying a small amount of water to the circular film and allowing it to absorb water therein was attached to the back of the hand. The period of time until the peeling of the film starts, feeling upon use, and the state after the film was peeled off were tested and results are shown in Table 1.
EXAMPLE 3
[0000] <Preparation of Wetly Shear-Triturated Low-Substituted Cellulose Ether>
[0073] In the same manner as in Example 1 except that the low-substituted hydroxypropyl cellulose of Example 1 was replaced with a low-substituted methyl cellulose (molar substitution degree of a methoxyl group: 0.28), a wetly shear-titrated low-substituted cellulose ether was obtained. The resulting slurry was thickened and became creamy. The measurement with laser scattering particle size distribution analyzer “HORIBA LA-90” (product of Horiba, Ltd.) showed an average particle size of 16 μm.
[0000] <Preparation of Film>
[0074] The 87.5 g (solid content: 3.5 g) of 4 wt % slurry containing the wetly shear-titrated the low-substituted methyl cellulose and 15 g (solid content: 1.5 g) of a 10 wt % aqueous solution of hydroxypropylmethyl cellulose (product of Shin-Etsu Chemical Co., Ltd.; molar substitution of the methoxyl group: 1.3; that of the hydroxypropoxyl group: 0.21, the viscosity of a 2 wt % aqueous solution at 20° C.: 100 mPa·s) were mixed. To the resulting mixture, 1.5 g of α-tocopherol and 0.64 g of ascorbic acid were added and then mixed with stirring at 300 rpm, whereby a uniform creamy emulsion was obtained.
[0075] The resulting emulsion was cast onto a glass plate to form a film having a thickness of 1.5 mm. The film was dried in a blast oven at 60° C., whereby a transparent continuous film having a thickness of 70 μm and the below-described composition was obtained.
Low-substituted cellulose ether/water-soluble cellulose ether: 7/3 (weight ratio) Low-substituted methyl cellulose: 46.4 wt % Hydroxypropylmethyl cellulose: 19.9 wt % α-Tocopherol: 20.0 wt % Ascorbic acid: 8.6 wt % Water: 5.1 wt %
[0082] The film was punched out into a circular film of 2.5 cm in diameter and was used as a sample for evaluation.
[0083] A hydrous sheet obtained by applying a small amount of water to the circular film and allowing it to absorb water therein was attached to the back of the hand. The period of time until the peeling of the film starts, feeling upon use, and the state after the film was peeling were tested and results are shown in Table 1.
EXAMPLE 4
[0000] <Preparation of Wetly Shear-Triturated Low-Substituted Cellulose Ether>
[0084] In a same manner as in Example 1 except that the low-substituted hydroxypropyl cellulose used in Example 1 was replaced with low-substituted hydroxypropylmethyl cellulose (product of Shin-Etsu Chemical CO., Ltd.; molar substitution degree of a methoxyl group: 0.13; that of a hydroxypropoxyl group: 0.18), wetly shear-triturated low-substituted cellulose ether was obtained. The slurry was thickened and became creamy. The measurement with a laser scattering particle size distribution analyzer “HORIBA LA-90” (product of Horiba, Ltd.) showed an average particle size of 16 μm.
[0000] <Preparation of Film>
[0085] The 112.5 g (solid content: 4.5 g) of 4 wt % slurry containing the wetly shear-triturated low-substituted hydroxypropylmethyl cellulose and 2.5 g (solid content: 0.25 g) of a 10 wt % aqueous solution of hydroxypropylmethyl cellulose (product of Shin-Etsu Chemical Co., Ltd.; molar substitution degree of a methoxyl group: 1.8; that of a hydroxyproxyl group: 0.16; the viscosity of a 2 wt % aqueous solution at 20° C.: 5 mPa·s) were mixed. To the resulting mixture, 1.07 g of α-tocopherol and 1.07 g of glycerin were added and then were mixed with stirring at 300 rpm, whereby a uniform creamy emulsion was obtained.
[0086] The emulsion was cast onto a glass plate so as to form a film having a thickness of 1.5 mm. The film was dried in a blast oven at 60° C., whereby a transparent continuous film having a thickness of 70 μm and the below-described composition was obtained.
Low-substituted cellulose ether/water-soluble cellulose ether: 9/1 (weight ratio) Low-substituted hydroxypropylmethyl cellulose: 60.0 wt % Hydroxypropylmethyl cellulose: 6.6 wt % α-Tocopherol: 14.2 wt % Glycerin: 14.2 wt % Water: 5.0 wt %
[0093] The film was punched out into a circular film of 2.5 cm in diameter and was used as a sample for evaluation.
[0094] A hydrous sheet obtained by applying a small amount of water to the circular film and allowing it to absorb water therein was attached to the back of the hand. The period of time until the peeling of the film starts, feeling upon use, and the state after the film was peeled off were tested and results are shown in Table 1.
COMPARATIVE EXAMPLE 1
[0095] A 10 wt % aqueous dispersion of the low-substituted hydroxypropyl cellulose powder (product of Shin-Etsu Chemical Co., Ltd.; molar substitution of 0.25) which was employed as a raw material for the wetly shear-triturated product in Example 1 was prepared. The measurement of an average particle size with a laser scattering particle size distribution analyzer “HORIBA LA-90” (product of Horiba, Ltd.) showed 150 μm. The 35.0 g (solid content: 3.5 g) of the resulting dispersion and 15 g (solid content: 1.5 g) of a 10 wt % aqueous solution of hydroxypropylmethyl cellulose (product of Shin-Etsu Chemical Co., Ltd.; molar substitution degree of a methoxyl group: 1.87; that of a hydroxypropoxyl group: 0.23; viscosity of a 2 wt % aqueous solution at 20° C.: 6 mPa·s) were mixed with stirring at 300 rpm. To the resulting mixture, 1.07 g of α-tocopherol and 1.07 g of ascorbic acid were added and then mixed with stirring at 300 rpm.
[0096] The resulting dispersion was cast onto a glass plate so as to form a film having a thickness of 1.0 mm. The film was dried in a blast oven at 60° C., whereby a film having transparency in some parts and white discontinuous powder deposits in some parts was obtained. The film strength was low. When the film was wetted with a small amount of water, it lost its shape so that it could not be subjected to the test for adhesion to the skin.
COMPARATIVE EXAMPLE 2
[0097] The low-substituted hydroxypropyl cellulose powder (product of Shin-Etsu Chemical Co., Ltd.; molar substitution degree of 0.25) used as a raw material for the wetly shear-triturated product in Example 1 was finely pulverized with a dry jet mill to prepare a 10 wt % aqueous dispersion thereof. The measurement of an average particle size of the aqueous dispersion with a laser scattering particle size distribution analyzer “HORIBA LA-90” (product of Horiba, Ltd.) showed 60 μm. The 35.0 g (solid content: 3.5 g) of the resulting aqueous dispersion and 15 g (solid content: 1.5 g) of a 10 wt % aqueous solution of “Hydroxypropylmethyl cellulose 2910” (product of Shin-Etsu Chemical Co., Ltd.; molar substitution degree of a methoxyl group: 1.87; that of a hydroxypropoxyl group: 0.23; viscosity of a 2 wt % aqueous solution at 20° C.: 6 mPa·s) were mixed with stirring at 300 rpm. To the resulting mixture, 1.07 g of α-tocopherol and 1.07 g of ascorbic acid were added and mixed with stirring at 300 rpm.
[0098] The resulting dispersion was cast onto a glass plate so as to form a film having a thickness of 1.0 mm. The film was dried with a blast oven at 60° C., whereby a film having transparency in some parts and white discontinuous powder deposits in some parts was obtained. The film strength was low. When the film was wetted with a small amount of water, it lost its shape so that it could not be subjected to the test for adhesion to the skin.
COMPARATIVE EXAMPLE 3
[0099] The low-substituted hydroxypropyl cellulose powder (product of Shin-Etsu Chemical Co., Ltd.; molar substitution degree of 0.25) which was a raw material for the wetly shear-triturated product in Example 1 was finely pulverized with a dry jet mill. A 7 wt % aqueous dispersion of the resulting fine powder was wetly shear-triturated with a pulverizer of stone-mortar type (“Cerendipitor MKCA6-3INV”, product of Masuko Sangyo Co., Ltd.) under the following conditions:
clearance between the upper and lower grinders: 80 micron, rotation speed: 1500 rpm (peripheral speed: 11.7 m/sec), and treating velocity; 1.5 kg/min.
[0101] This operation was repeated 5 times to yield wetly shear-triturated low-substituted hydroxypropyl cellulose. The slurry thus obtained was thickened slightly. The measurement of an average particle size with a laser scattering particle size distribution analyzer “HORIBA LA-90” (product of Horiba, Ltd.) showed 40 μm.
[0102] The 50.0 g (solid content: 3.5 g) of the aqueous dispersion and 15 g (solid content: 1.5 g) of a 10 wt % aqueous solution of hydroxypropylmethyl cellulose (product of Shin-Etsu Chemical Co., Ltd.; molar substitution degree of the methoxyl group: 1.87; that of the hydroxypropoxyl group: 0.23; the viscosity of a 2 wt % aqueous solution at 20° C.: 6 mPa·s) were mixed with stirring at 300 rpm. To the resulting mixture, 1.07 g of α-tocopherol and 1.07 g of ascorbic acid were added and mixed with stirring at 300 rpm.
[0103] The resulting dispersion was cast onto a glass plate so as to form a film having a thickness of 1.0 mm. The film was dried with a blast oven at 60° C., whereby a film having transparency in some parts and white discontinuous powder deposits in some parts was obtained. The film strength was low. When the film was wetted with a small amount of water, it lost its shape so that it could not be subjected to the test for adhesion to the skin.
COMPARATIVE EXAMPLE 4
[0104] To 125.0 g (solid content: 5.0 g) of the 4 wt % slurry of the wetly shear-triturated low-substituted hydroxypropyl cellulose prepared in the same manner as in Example 1, 1.07 g of glycerin and 1.07 g of ascorbic acid were added and mixed with stirring at 300 rpm to yield a uniform creamy emulsion. The emulsion was cast onto a glass plate so as to form a film having a thickness of 1.5 mm thickness. The film was dried with a blast oven at 60° C., whereby a transparent continuous film having a thickness of 50 μm and the below-described composition was obtained.
Low-substituted hydroxypropyl cellulose: 66.4 wt % Glycerin: 14.2 wt % Ascorbic acid: 14.2 wt % Water: 5.2 wt %
[0109] The resulting film was punched out into a circular film having a diameter of 2.5 cm and used as a sample for evaluation.
[0110] A hydrous sheet obtained by applying a small amount of water to the circular film and allowing it to absorb water therein was attached to the back of the hand. The period of time until the peeling of the film starts, feeling upon use, and the state after peeling were tested and results are shown in Table 1.
TABLE 1 Adhesion time to Skin state the skin after peeling (minute) Flexibility Adhesion of film Example 1 160 A A A Example 2 240 A A A Example 3 150 A A A Example 4 105 A A A Comp. Ex. 1 Film lost its shape when wetted with a small amount of water Comp. Ex. 2 Film lost its shape when wetted with a small amount of water Comp. Ex. 3 Film lost its shape when wetted with a small amount of water Comp. Ex. 4 20 B C B
[0111] In Table 1, “flexibility” is evaluated based on the following criteria:
A: flexible and elastic, B: flexible but less elastic, and C: not flexible.
[0115] “Adhesion” is evaluated based on the following criteria:
A: good adhesion to the skin, B: not so good adhesion to the skin, and C: poor adhesion to the skin.
[0119] “Skin state after peeling” is evaluated based on the following criteria:
A: moist-and smooth, B: slightly moisturized feeling, and C: no improvement.
[0123] The results shown in Table 1 proved that the hydrous sheets obtained in Examples were excellent in skin adhesion and feeling upon use. | An object is to provide a film preparation comprising a polymer harmless to living bodies and being highly adhesive to the skin; and a film preparation further containing a pharmaceutically active oily ingredient and being highly adhesive to the skin. More specifically, provided is a film preparation comprising a drug, a wetly shear-triturated low-substituted cellulose ether having a molar substitution of from 0.05 to 1.0 per anhydrous glucose unit, and a water-soluble cellulose ether, and having 100 minutes or greater of adhesion ability to the skin. The preparation becomes a skin-adhesive hydrous sheet having excellent skin adhesion after it is wet with water as it is used. | 0 |
This application is a division of application Ser. No. 08/452,142, filed May 26, 1995, now U.S. Pat. No. 5,658,657.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of producing a reclaimed joint sheet among joint sheets used as a material of a gasket or a packing for automobiles, ships, various machineries and equipments and the like.
2. Description of the Related Art
The joint sheet is produced by inserting a composition for the formation of the joint sheet comprising inorganic fibers or organic fibers or a mixture thereof, a rubber material, rubber chemicals and a filler between a pair of a hot roll and a cold roll to heat and roll the composition, laminating the composition on the hot roll in form of a sheet, and then peeling off the laminated sheet from the hot roll. Next, the resulting sheet is punched out in a shape to be used as a packing.
However, when the joint sheet is punched out in form of a packing, a great amount of punched pieces corresponding to 60-70% of the joint sheet are created, so that there are problems that the material yield is low and the cost is increased.
SUMMARY OF THE INVENTION
It is, therefore, an object of the invention to solve the aforementioned problems and to provide a reclaimed joint sheet and a method of producing the same.
According to a first aspect of the invention, a composition for the formation of the joint sheet comprising inorganic fibers or organic fibers or a mixture thereof, a rubber material, rubber chemicals and a filler is kneaded and inserted between a pair of a hot roll and a cold roll to heat and roll the composition, at where the composition is heated and rolled to laminate on the hot roll in form of a sheet, and then the laminated sheet is peeled off from the hot roll to obtain a joint sheet, which is punched out in a shape to be used to form a packing, during which the punched pieces of the joint sheet are finely pulverized into particles having a particle size of not more than 1.4 mm by means of a grinder and added to the same composition for the formation of the joint sheet as mentioned above in an amount of not more than 50 weight % to produce a reclaimed joint sheet in the same manner as mentioned above.
According to a second aspect of the invention, a reclaimed joint sheet is constituted with a first layer of a joint sheet made from a composition for the formation of the joint sheet comprising inorganic fibers or organic fibers or a mixture thereof, a rubber material, rubber chemicals and a filler, a second layer of a joint sheet made by finely pulverizing punched pieces obtained after the punching out of the above joint sheet into a shape to be used as a packing into particles having a particle size of not more than 1.4 mm by means of a grinder and then adding to the same composition for the formation of the joint sheet in an amount of not more than 50 weight %, and a third layer of the same joint sheet as the first layer.
The term "punched pieces" used herein means to include redundant scraps of the composition in the formation of the sheet, defective goods, a fragment at cutting step in addition to pieces produced in the punching of the sheet.
As mentioned above, according to the invention, since pieces of the joint sheet produced in the conventional punching of the joint sheet in form of a packing can be reused, not only the material yield is improved and the cost is decreased, but also industrial wastes are decreased. Furthermore, each of the first and third layers in the reclaimed joint sheet according to the invention as an outer face is made from a joint sheet not including the punched pieces of the joint sheet, so that the seal surface becomes smooth and even and consequently sufficient sealing performance can be developed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the accompanying drawings, wherein:
FIG. 1 is a schematic view illustrating a method of producing a joint sheet;
FIG. 2 is a partially enlarged sectional view of the conventional sheet laminate laminated on a hot roll;
FIG. 3 is a partially enlarged sectional view illustrating an embodiment of the reclaimed joint sheet according to invention laminated on the hot roll; and
FIG. 4 is a graph showing a relation between an amount of punched pieces added and a tensile strength of the resulting reclaimed sheet.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the invention, a composition 1 for the formation of the joint sheet comprising inorganic fibers or organic fibers or a mixture thereof, a rubber material, rubber chemicals and a filler, which is kneaded, for example, in an agitator (see FIG. 1), is inserted between a pair of a hot roll 2 and a cold roll 3, at where the composition 1 is heated and rolled to laminate the composition 1 on the hot roll 2 in form of a sheet 4. The laminated sheet 4 is peeled off from the hot roll and punched out into a shape to be used as a packing. Then, the punched pieces of the joint sheet are finely pulverized into particles having a particle size of not more than 1.4 mm by means of a grinder and added to the same composition for the formation of the joint sheet as mentioned above in an amount of not more than 50 weight % to produce a reclaimed joint sheet.
In FIG. 1, numeral 5 is a guide for recovering a solvent such as toluene or the like disposed above the cold roll 3, and numeral 6 a solvent recovering vessel. FIG. 2 is a partially enlarged sectional view of the conventional sheet laminate 4 laminated on the hot roll 2, in which numeral 4a is a first layer of the sheet laminate and numeral 4b a second layer thereof. FIG. 3 is a partially enlarged sectional view of a reclaimed joint sheet 7 of three layer construction according to the invention laminated on the hot roll 3, in which numeral 7a is a first layer, numeral 7b a second layer and numeral 7c a third layer.
As the inorganic fiber, use may be made of glass fiber, rock wool, various ceramic fibers, carbon fiber and metal fiber.
As the organic fiber, use may be made of aromatic polyamide fiber, fibrillated aromatic polyamide fiber, polyamide fiber, polyolefine fiber and the like.
These inorganic fibers and organic fibers may be used alone or in admixture thereof. In case of the mixture of the inorganic fiber and organic fiber, the mixing ratio of the inorganic fiber to the organic fiber is generally about 1:1-4:1 in weight ratio. Furthermore, these fibers are compounded into the joint sheet in an amount of about 10-60 weight %.
As the rubber material, use may be made of nitrile rubber (NBR), styrene-butadiene rubber (SBR), isoprene rubber (IR), chloroprene rubber (CR), ethylenepropylene rubber (EPM), fluororubber (FPM), silicone rubber (SI) and the like. The rubber material is compounded into the joint sheet in an amount of about 10-30 weight %.
As the rubber chemicals, there are used a vulcanizing agent such as sulfur, zinc oxide, magnesium oxide or the like, and a vulcanization accelerator such as thiazole compound, polyamine compound, sulfenamide compound, guanidine compound or the like. The rubber chemicals are compounded into the joint sheet in an amount of about 0.5-10 weight %.
As the filler, use may be made of clay, talc, barium sulfate, sodium bicarbonate, graphite, calcium carbonate, carbon black, diatomaceous earth, mica, aluminum sulfate, alumina hydrate, magnesium carbonate and the like. The filler is compounded into the joint sheet in an amount of about 10-70 weight %.
An example of a first composition for the first layer 4a shown in FIG. 2 is shown as follows.
______________________________________Fibrillated aromatic polyamide fiber 15 weight %NBR 12 weight %Rubber chemicals 3 weight %Filler 70 weight %Toluene 0.4 l per 1 kg of the above mentioned mixture______________________________________
An example of a second composition for the second layer 4b shown in FIG. 2 is shown as follows.
______________________________________Fibrillated aromatic polyamide fiber 10 weight %Glass fiber 10 weight %NBR 18 weight %Rubber chemicals 2 weight %Filler 60 weight %Toluene 0.4 l per 1 kg of the above mentioned mixture______________________________________
The above first and second compositions are used to produce a joint sheet as follows. At first, the first composition is inserted between a hot roll 2 heated to 120°-150° C. and a cold roll 3 maintained at 30°-50° C. When a thickness of the first composition reaches to 10-20% of a thickness of a desired sheet, the second composition is added onto the first composition to form a sheet laminate shown in FIG. 2. In this case, a pressure between the rolls 2, 3 is maintained at about 20-40 bar. Thereafter, the sheet laminate is subjected to a vulcanization treatment at an ambient temperature of 100°-150° C. in a drying furnace for 30-60 minutes. The thus obtained joint sheet is subjected to a punching and used as a packing.
According to the invention, the punched pieces of the above joint sheet are charged into a grinder, at where they are finely pulverized at 5000 rpm into particles having a particle size of not more than 1.4 mm and added to the same composition as mentioned above for reuse.
In the reclaimed joint sheet according to the invention, the amount of the punched pieces added is practically suitable to be not more than 50 weight %. An example of a composition for the formation of the reclaimed joint sheet containing 10 weight %, 30 weight % or 50 weight % of the punched pieces is shown as follows.
______________________________________Punched pieces 10 weight % 30 weight % 50 weight %Fibrillated aromatic 18 weight % 6.5 weight % 4 weight %polyamide fiberGlass fiber 18 weight % 6.5 weight % 4 weight %NBR 18 weight % 18 weight % 18 weight %Rubber chemicals 2 weight % 2 weight % 2 weight %Filler 52 weight % 37 weight % 22 weight %Toluene 0.4 l per 1 kg of the above mentioned mixture______________________________________
Moreover, an embodiment of the reclaimed joint sheet 7 shown in FIG. 3 is shown as follows.
______________________________________ first layer second layer third layerLayer (7a) (7b) (7c)______________________________________Fibrillated aromatic 15 weight % 6.4 weight % 10 weight %polyamide fiberGlass fiber -- 6.4 weight % --NBR 12 weight % 15 weight % 18 weight %Rubber chemicals 3 weight % 2 weight % 2 weight %Filler 70 weight % 70.2 weight % 70 weight %Punched pieces -- 30 weight % --Toluene 0.4 l per 1 kg of the above mentioned mixture______________________________________
The above compositions are used to produce a reclaimed joint sheet as follows. At first, the composition for the first layer 7a is inserted between the hot roll 2 heated to 120°-150° C. and the cold roll 3 maintained at 30°-50° C. When a thickness of the composition reaches to 10-20% of a thickness of a desired sheet, the composition for the second layer 7b is inserted between the hot roll and the cold roll. When a thickness of the composition on the first layer reaches to 70-80% of the thickness of the desired sheet, the composition for the third layer 7c is inserted between the hot roll and the cold roll to form a reclaimed joint sheet. In this case, a pressure between the rolls 2, 3 is maintained at about 20-40 bar. Thereafter, the sheet laminate is subjected to a vulcanization treatment at an ambient temperature of 100°-150° C. in a drying furnace for 30-60 minutes.
In the present invention, the reason why the particle size in the fine pulverization of the punched pieces is limited to not more than 1.4 mm is due to the fact that when the particle size-exceeds 1.4 mm, the particle size as an additive becomes too coarse to lower the quality of the reclaimed joint sheet. Further, the reason why the amount of the punched pieces added is limited to not more than 50 weight % is due to the fact that when the amount exceeds 50 weight %, the quality of the reclaimed joint sheet is degraded. That is, when the punched pieces are added in an amount of more than 50 weight %, as shown in FIG. 4, the adhesion of the composition to the cold roll is caused in the formation of the sheet and the quality of the resulting reclaimed joint sheet is frequently degraded.
As mentioned above, according to the invention, the punched pieces of the joint sheet after the punching of the joint sheet as a packing can be reused, so that not only the material yield is improved and the cost is decreased, but also industrial wastes are reduced. Further, each of the first and third layers in the reclaimed joint sheet according to the invention is made from a joint sheet containing no punched pieces of the joint sheet, so that the seal surface of the joint sheet becomes smooth and even, and hence the sufficient sealing performance can be developed. | A reclaimed joint sheet used as a gasket or packing member for automobiles, ships and the like consists of a first layer of a joint sheet made from a given composition, a second layer of a joint sheet made by mixing finely pulverized pieces of the joint sheet after the punching out of the joint sheet having a given particle size with the same composition for the formation of the joint sheet, and a third layer of the same joint sheet as the first layer. | 1 |
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a bidirectional switching circuit, more particularly a switching circuit for triggering a bidirectional thyristor such as TRIAC which is a trademark of a product of General Electric, Inc. of U.S.A.
(b) Description of the Prior Art
A bidirectional thyristor, in general, when employed as, for example, a power controlling element of a power supply circuit requires a switching circuit as a triggering element or a circuit for triggering this bidirectional thyristor. As the triggering elements of this type, there have been proposed and placed on the market various elements such as DIAC (Diode AC Switch), SBS (Silicon Bilateral Switch) and PUT (Programmable Uni-Junction Transistor). Among them, a DIAC is arranged to be operative so that, for example, in such circuit as shown in FIG. 1, when a voltage which is applied to a DIAC 4 across terminals 1 and 2 and via a resistor 3 has reached a certain value (usually about 30 V), the electric charge which has been stored in a capacitor 5 is caused to flow to a gate of a bidirectional thyristor 6 to render this thyristor 6 conductive. And, by the use of this circuit, it is possible to control the firing angle of the bidirectional thyristor 6 by varying the resistance value of the resistor 3.
Also, as SBS may be expressed by its equivalent circuit which is of such arrangement as shown in FIG. 2A. For example, in a circuit shown in FIG. 2B (which is a circuit as shown in FIG. 1 wherein the DIAC 4 is substituted by an SBS 7), the SBS is designed to be operative so that, when a voltage applied to the SBS 7 has reached a certain voltage level (usually about 8 V), the bidirectional thyristor 6 is rendered conductive in a manner same as that performed by the aforesaid DIAC.
Furthermore, a PUT may be expressed by an equivalent circuit which is arranged as shown in FIG. 3A. This PUT is used in a manner as, for example, shown in FIG. 3B. This circuit shown in FIG. 3B is intended, in a circuit for supplying to a load 23 an ac voltage applied across terminals 21 and 22, to trigger by a PUT 25 a bidirectional thyristor 24 which is inserted between the terminal 22 and the load 23. Since this PUT is a uni-directional element, this circuit is provided with a rectifying circuit 26 for driving the PUT 25 and a driving circuit 28 which is comprised of a Zener diode 27 and other elements. This circuit is arranged to be operative so that, when the PUT 25 is rendered conductive, an electric current is allowed to flow to the primary side of a transformer 29, and that the bidirectional thyristor 24 is triggered by a voltage induced on the secondary side of the transformer 29.
Among those elements described above, the DIAC and the SBS have the inconveniences such that, when these elements are employed in such circuits as shown in FIG. 1 and FIG. 2B, the charge-up time of the capacitor 5 varies in accordance with the frequency of the voltage applied across the terminals 1 and 2, so that the timing at which the DIAC 4 or the SBS 7 is rendered conductive will vary in accordance with this frequency. Thus, there is the drawback that the values of the resistor 3 and the capacitor 5 require to be varied in accordance with the frequency of the voltage which is applied. More particularly, in the circuits shown in FIG. 1 and FIG. 2B wherein these elements are employed, if the values of the resistor 3 and the capacitor 5 are set in such way that, for example, these circuits are actuated by a commercial power supply with a frequency of 50 Hz, there could happen that the timing for rendering the DIAC 4 or the SBS 7 conductive is influenced by the power supply frequency in such manner that there arises an instances wherein the circuits are not actuated by a commercial power supply with a frequency of 60 Hz. Also, when such circuitry is connected to a power supply, if a commercial power is applied, for example, at half-way of a half cycle of the power which is supplied, the charge-up of the capacitor 5 will be commenced exactly at the time the commercial power is applied. Therefore, there will arise an instance wherein there is not performed a charge-up of the capacitor 5 to an extent enough for rendering either the DIAC 4 or the SBS 7 conductive before the termination of this half cycle. Such operations will constitute factors to make the set firing angle unstable.
Also, in case the circuit shown in FIG. 1 or FIG. 2B is a circuit intended for controlling the power of the power supply circuit, i.e. in case it is a circuit arranged so that the bidirectional thyristor 6 shown in these Figures is inserted in a power supply line for a load, and that the resistor 3 is comprised of a variable resistor, so as to be operative that the fluctuation of the voltage applied to the load is detected to control the value of this resistor 3 to compensate for said fluctuation of the voltage to thereby control the firing angle of the bidirectional thyristor 6, there will arise the following problem. That is, because the controlling of the resistor 3 is performed only when the bidirectional thyristor 6 is rendered conductive at the time the circuit is connected to the power supply, there would arise an instance wherein the actuation of the bidirectional thyristor 6 is not carried out at all depending on the condition of the resistor 3 at the time the circuit is connected to the power supply, i.e. an instance wherein the value of the resistor 3 is extremely large so that the capacitor 5 is not charged up. Thus, there is the drawback that the actuation of the bidirectional thyristor 6 becomes unstable. Furthermore, such known arrangement, in conjunction with the inconvenience that the timing at which the bidirectional thyristor 6 is rendered conductive would vary depending on the difference in the power supply frequency such as 50 Hz and 60 Hz, would make the actuation of the bidirectional thyristor 6 all the more unstable.
Also, the PUT, when used in such manner as shown in FIG. 3B, is able to eliminate the drawback and inconvenience of the aforesaid DIAC and SBS. On the other hand, however, the PUT has no bidirectional characteristic, so that there is required a driving circuit 28 having such complicated arrangement as shown in FIG. 3B, and also there is required a transformer 29. Thus, the PUT has the drawback that the resulting circuit becomes costly.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the present invention is to provide a bidirectional switching circuit, having a control terminal, which permits its bidirectional current flow.
Another object of the present invention is to provide a trigger circuit for a bidirectional thyristor, which is able to perform actuation of the bidirectional thyristor without being substantially affected by the frequency of power supply.
Still another object of the present invention is to provide a trigger circuit for a bidirectional thyristor as described above, which is able to perform with certainty the actuation of the bidirectional thyristor without being substantially affected by the fluctuation of the power supply voltage.
Yet another object of the present invention is to provide a trigger circuit for a bidirectional thyristor as described above, which, even when it is utilized for a bidirectional thyristor intended for power-controlling of the power supply circuit, is able to perform, with certainty, the actuation of the bidirectional thyristor.
A further object of the present invention is to provide a trigger circuit for a bidirectional thyristor as described above, which can be materialized with a simple circuit arrangement, and which does not produce any big problem with respect to the fabricating cost of the circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a known trigger circuit diagram employing a DIAC.
FIG. 2A is a known equivalent circuit diagram of an SBS.
FIG. 2B is a known trigger circuit diagram employing an SBS.
FIG. 3A is a known equivalent circuit diagram of a PUT.
FIG. 3B is a known trigger circuit diagram employing a PUT.
FIG. 4 is a diagram of an embodiment of a bidirectional switching circuit according to the present invention.
FIG. 5 is a voltage-to-current characteristic chart of the bidirectional switching circuit shown in FIG. 4.
FIG. 6 is a diagram of a circuit substituting a series circuit of Zener diodes shown in FIG. 4.
FIG. 7 is a diagram of a power supply circuit incorporating the switching circuit shown in FIG. 4.
FIG. 8 is a diagram for explaining the triggering action of the circuit shown in FIG. 7.
FIG. 9 is a diagram of a stabilized power supply circuit incorporating the switching circuit shown in FIG. 4.
FIG. 10 is a concrete circuit diagram of the stabilized power supply circuit shown in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some embodiments of the present invention will hereunder be described by referring to FIGS. 4 to 10.
FIG. 4 is a circuit diagram showing the arrangement of a bidirectional switching circuit A according to the present invention. In FIG. 4, reference numerals 41 and 42 represent a first terminal and a second terminal, respectively, and 43 a controlling terminal. Between the first terminal 41 and the controlling terminal 43 is connected a resistor 44. Between the controlling terminal 43 and the second terminal 42 are connected Zener diodes 45 and 46 in series. In this instance, the Zener diode 45 is forward from the controlling terminal 43 toward the second terminal 42, whereas the Zener diode 46 is forward from the second terminal 42 toward the controlling terminal 43. And, the controlling terminal 43 is connected to a base of a pnp-type transistor 47, and also to a collector of an npn-type transistor 48, and further to a base of an npn-type transistor 49 and also to a collector of a pnp-type transistor 50. Furthermore, the first terminal 41 is connected to an emitter of the transistor 47, and to an emitter of the transistor 49. Also, the second terminal 42 is connected to the collector of the transistor 47 via a diode 51 and a resistor 52 which are connected in series in this order, and also to the base of the transistor 48. Concurrently therewith, said second terminal 42 is connected to the collector of the transistor 49 via a diode 53 and a resistor 54 which are connected in series in this order, and to the base of the transistor 50. In this instance, the diode 51 is forward from the resistor 52 toward the second terminal 42, whereas the diode 53 is forward from the second terminal 42 toward the resistor 54. Also, the emitter of the transistor 48 is connected to a connecting point of the diode 51 and the resistor 52. The emitter of the transistor 50 is connected to a connecting point of the diode 53 and the resistor 54. In the arrangement described above, the transistors 47 and 48, and the resistor 52 jointly constitute a first circuit means 55 which is operated in such manner that, when the relationship between the voltages applied to the said respective terminals 41 to 43 satisfies a certain condition which will be described later, conduction is established between the first terminal 41 and the second terminal 42 in a direction from the terminal 41 toward the terminal 42, and also that this conducting state is self-held. Similarly, the transistors 49 and 50, and the resistor 54 jointly constitutes a second circuit means 56 which is operative so that, when the aforesaid voltage relationship satisfies another condition which will be also described later, conduction is established between the second terminal 42 and the first terminal 41 in a direction from the terminal 42 toward the terminal 41, and also that this conducting state is self-held.
Description will next be made of the operation of the switching circuit A having the foregoing arrangement.
To begin with, this switching circuit A is operative so that, when a predetermined voltage is applied across the first and the second terminals 41 and 42 and when the value of this applied voltage rises above a breakover voltage, V z , conduction is established between these first and second terminals 41 and 42 with a bidirectional characteristic. For example, let us assume that a predetermined voltage is applied across the first and the second terminals 41 and 42, and that the relationship between the potential V A1 at the first terminal 41 and the potential V A2 at the second terminal 42 is V A1 >V A2 . Under such assumption as mentioned above, if the base-emitter voltage of the transistor 47 is assumed to be V BE1 , and the forward voltage drop of the Zener diode 45 is designated as V F1 , and also the Zener voltage of the Zener diode 46 as V R1 and if there is obtained the relationship: V A1 -V A2 >V BE1 +V F1 +V R1 , the Zener diodes 45 and 46 are rendered conductive, so that the transistors 47 and 48 are both rendered conductive, whereby conduction is established between the first and the second terminals 41 and 42. More particularly, in this state, an electric current is allowed to flow between the first and the second terminals 41 and 42 through the paths as indicated by the solid line and the broken lines in FIG. 4. In such instance, the lowest operating voltage V z required for the circuit A to become conductive is: V z =V BE1 +V F1 +V R1 . In view of the fact that voltages V BE1 and V F1 are both trifle voltages, said voltage V z is determined mainly by the voltage V R1 .
Also, in case there is obtained the relationship: V A2 -V A1 >V BE2 +V F2 +V R2 (wherein: V BE2 represents the base-emitter voltage of the transistor 49, V F2 represents the forward voltage drop of the Zener diode 46, and V R2 represents the Zener voltage of the Zener diode 45) when the relationship between the aforesaid potentials V A1 and V A2 is V A1 <V A2 , the Zener diodes 45 and 46 are rendered conductive in the same manner as that described above, and accordingly the transistors 49 and 50 are also rendered conductive, whereby conduction is established between the first and the second terminals 41 and 42. In this instance, the current paths between the first and second terminals 41 and 42 will be the paths as indicated by a one-dot chain line and two-dots chain lines in FIG. 4. It should be understood here that in the aforesaid respective operations, the diodes 51 and 53 serve to prevent the application of a reverse voltage across the emitter and the base of the transistors 48 and 50. And, the voltage-to-current characteristic of the switching circuit A in these operations will be as shown in FIG. 5. It should be noted here also that, in the subsequent description, these operations will be called generally a first behavior.
The aforesaid switching circuit A is operative so that, even when the value of the voltage applied across the first and the second terminals 41 and 42 is less than V z , conduction is established between these first and second terminals 41 and 42 with a bidirectional characteristic in accordance with the value of the voltage V G which is applied to the controlling terminal 43. Let us suppose, for example, that the relationship between the potential V A1 at the first terminal 41 and the potential V A2 at the second terminal 42 is V A1 >V A2 . Then, in case the relationship between the potential V A1 at the first terminal 41 and the potential V G at the controlling terminal 43 (which are potentials relative to the second terminal 42) has become: V A1 >V G +V BE1 , the transistors 47 and 48 are rendered conductive so that conduction will be established between the first and the second terminals 41 and 42 in such way that a current is allowed to flow as indicated by the broken lines in FIG. 4. Also, in case a relationship: V A1 <V G +V BE2 is obtained when the relationship between said potentials V A1 and V A2 is V A1 <V A2 , the transistors 49 and 50 are rendered conductive, so that conduction is established between the first and the second terminals 41 and 42 in such way that an electric current flows as indicated by two-dots chain lines shown in FIG. 4. It should be noted here that, in the following description, these operations are called generally a second behavior.
Thus, this switching circuit A is operative such that, by controlling the voltages applied to the first and the second terminals 41 and 42 and to the controlling terminal 43, "on-off" actions established between the first and the second terminals 41 and 42, whereby the bidirectional thyristor can be triggered by utilizing the electric current flowing across these terminals 41 and 42.
It should be understood also that, in the aforesaid switching circuit A, the series circuit of the Zener diodes 45 and 46 connected between the controlling terminal 43 and the second terminal 42 may be substituted by such circuit as that shown in FIG. 6. This circuit is comprised, in a bridge connection, of diodes 57a, 57b, 57c and 57d, and a Zener diode 58. In the diode bridge-type rectifying circuit which is arranged so that the respective cathodes of the diodes 57a and 57b are connected in common, that the respective anodes of the diodes 57c and 57d are connected in common, that the anode of the diode 57a is connected to the cathode of the diode 57d, and that the anode of the diode 57b is connected to the cathode of the diode 57c, the cathode of the Zener diode 58 and the anode thereof are connected to the common connecting point of said cathode and also to the common connecting point of said anodes, respectively. In this circuit, it should be understood that, in case a terminal Z 1 and a terminal Z 2 are connected to the controlling terminal 43 and the second terminal 42, respectively, in place of the series circuit comprised of the Zener diodes 45 and 46 in FIG. 4, the Zener voltage V R can be made equal for both directions between the first and the second terminals. In case a transformer is employed as a load as will be discussed later, it becomes especially necessary to make the positive and the negative firing angles equal to each other from the viewpoint of suppressing the occurrence of such inconveniences as magnetic deviation due to a dc bias current flow. That is, in case there is a difference between the positive firing angle and the negative firing angle, there will arise a difference between the positive region and the negative region of a waveshape of voltage, and this would be identical with the instance wherein either a positive or a negative dc bias current flows. For this reason, the variation of the current relative to the variation of voltage will become extremely great, which will lead to a damage of the bidirectional thyristor, and accordingly to the breakage of the windings of the transformer. Thus, there is the necessity for making the positive and the negative firing angles equal relative to the each other. In case arrangement is provided so as to obtain a Zener voltage V R by the use of such circuit as that shown in FIG. 6 for the purpose of prevention of the occurrence of, for example, a magnetic deviation due to a dc bias current, the employment of only one Zener diode would be enough. Therefore, it is possible to equalize the Zener voltages for both directions and also to equalize the positive and the negative firing angles with easiness without requiring such complicated procedure as the selection of Zener diodes having an identical characteristic which are necessary when two of them are used.
FIG. 7 is a circuit diagram showing an example of a power supply circuit provided with a trigger circuit indicated generally at B which contains therein the switching circuit A shown in FIG. 4. The power supply circuit shown therein arranged so that, in a circuit intended for supplying the power of the ac power supply 61 to a load 62, a bidirectional thyristor 63 is inserted in series between an ac power supply 61 and a load 62, so as to control the firing angle of this bidirectional thyristor 63 by the trigger circuit B. The arrangement of the circuit shown in FIG. 7 is such that the symbol A represents a bidirectional switching circuit having the arrangement shown in FIG. 4, and in this Figure it is indicated by a block. Between a first power supply terminal 61a and a second power supply terminal 61b of the ac power supply 61 are connected a resistor 64 and another resistor 65 in series in this order, and also inserted a variable resistor 66 and a capacitor 67 in series in this order. Also, between the second terminal 42 of the switching circuit A and the power supply terminal 61b is connected a resistor 68. And, this switching circuit A is arranged so that its first terminal 41 is connected to a connecting point 69 of the variable resistor 66 and the capacitor 67, and that the second terminal 42 is connected to the gate of the bidirectional thyristor 63, and also that the controlling terminal 43 is connected to a connecting point 70 of the resistors 64 and 65. In the circuit arrangement described above, the variable resistor 66 is a light-receiving section of such means as a photo-coupler, and is arranged so that its value will vary as the amount of light from a light-emitting section of such means as said photo-coupler is controlled in accordance with a voltage applied to the load 62.
Next, description will be made of the operation of the circuit having the foregoing arrangement.
To begin with, the value R v of the variable resistor 66 is such that, when the bidirectional thyristor 63 is in its "off" state, said light-emitting element does not emit light, so that it has a very high value. In case R v >>0 as stated above, the switching circuit A will perform the aforesaid second behavior. More particularly, under the foregoing condition, if the voltage V I at the power supply terminal 61a exhibits a gradual rise in, for example, its positive half cycle of the voltage V I , a charge-up current will flow to the capacitor 67 through the path: the power supply terminal 61a→the resistor 64→the controlling terminal 43 of the switching circuit A→the resistor 44 of the switching circuit A→the first terminal 41 of the switching circuit A. Thus, the capacitor 67 is charged up. And, as the voltage at the power supply terminal 61a gradually drops beyond its maximum value, and when the relationship between the voltage V c across the capacitor 67 and the voltage V 1 across the resistor 65 becomes V 1 <V c near the termination of the positive half cycle, the switching circuit A will perform the aforesaid second behavior, to thereby establish conduction between the first and the second terminals 41 and 42. Thus, this switching circuit A discharges the electric charge stored in the capacitor 67, to thereby supply a trigger pulse to the gate of the bidirectional thyristor 63. As a result, the bidirectional thyristor 63 is turned "on", and the voltage of the power supply 61 is supplied to the load 62. Also, this circuit will operate in the same way as that described above for the negative half cycle also.
When the bidirectional thyristor 63 is turned "on", the value R v of the variable resistor 66 will decrease owing to the fact that a predetermined voltage is applied to the load 62. And, in case this value R v has decreased up to a predetermined level, the trigger circuit A will perform the aforesaid first behavior. That is, at such time, a charge-up current is supplied to the capacitor 67 through the aforesaid path in case the voltage at the power supply terminal 61a makes a gradual rise for the positive half cycle for example, and at the same time, there is concurrently supplied a charge-up current also through the path: the power supply terminal 61a→the variable resistor 66. And, when there is brought about such condition that the value of said voltage V c exceeds the operating voltage V z of the switching circuit A, the switching circuit A will perform the first behavior in the manner as described above, so that conduction is established across the first terminal 41 and the second terminal 42, thereby supplying a trigger pulse to the bidirectional thyristor 63. Also, this circuit will operate in the same way as described above for the negative half cycle of the voltage V I . It should be understood here that, in case the value R v of the variable resistor 66 is large after the actuation of the bidirectional thyristor 63 and accordingly in case said voltage V c does not reach the aforesaid voltage V z , the switching circuit A will perform the second behavior to control the firing angle of the bidirectional thyristor 63.
FIG. 8 is a diagram showing the timing at which the switching circuit A is rendered conductive for the positive half cycle in the aforesaid operations. It should be understood here that V 1 is based on the assumed voltage across the resistor 65 when the connecting point 70 is not connected with the controlling terminal 43. As shown in FIG. 8, the switching circuit A is operative so that, when the voltage V c has exceeded, by a voltage V BE1 , the voltage V 1 near the termination of the positive half cycle of the voltage V 1 , the switching circuit A performs the second behavior so as to turn the bidirectional thyristor 63 "on". When, subsequently, the level of the voltage V c has exceeded the level of the operating voltage V z of the switching circuit A, the switching circuit A performs the first behavior to turn the bidirectional thyristor 63 "on".
The circuit shown in FIG. 7 is operative so that, initially, it actuates the bidirectional thyristor 63 by the second behavior of the switching circuit A, and thereafter it controls the firing angle of this bidirectional thyristor by the first and the second behaviors of said switching circuit A. In such instance, the extent of the control of the firing angle for the bidirectional thyristor 63 would become extremely broad because the respective scopes of the first and second behavior are combined together. In this circuit of FIG. 7, when the bidirectional thyristor 63 is actuated near the termination of the half cycle of the power supply voltage V I , the actuation of the bidirectional thyristor is performed by the second behavior of the switching circuit A based on a comparison between the voltage V c and the voltage V 1 . Because of such behavior of the circuit, even in case the frequency of the voltage of the ac power supply 61 is switched between, for example, 60 Hz and 50 Hz, the actuation of the bidirectional thyristor 63 can be performed without fail. Also, even when the voltage of the power supply 61 fluctuates, it is also possible to actuate the bidirectional thyristor 63 without fail due to the same reason as that stated above.
FIG. 9 is a diagram showing an example of stabilized power supply circuit which is provided with the trigger circuit B shown in FIG. 7. The stabilized power supply circuit shown therein is an example of concrete circuit arrangement of the power supply circut shown in FIG. 7. In this Figure, those constitutional elements and parts similar to those of FIG. 7 are indicated by like reference numerals and symbols. The stabilized power supply circuit shown in FIG. 9 is arranged so that a power supply voltage V I across power supply terminals 61a and 61b is supplied to the primary winding of a transformer 71 via a bidirectional thyristor 63 which is controlled of its firing angle by a trigger circuit B, and the voltage derived across the secondary winding of the transformer 71 is subjected to rectification and smoothing by a rectifying circuit 72, so as to be supplied to a load 62. This stabilized power supply circuit is intended to be operative so that the fluctuation of the voltage applied to the load 62 or the fluctuation of the power consumed by the load 62 is detected by a detecting circuit 73, and that the value of a variable resistor 66 is controlled by a controlling circuit 74 based on the result of the detection. With this stabilized power supply circuit, the firing angle of the bidirectional thyristor 63 is controlled by the trigger circuit B in accordance with the voltage applied to the load 62, whereby the power which is supplied to the load 62 via the transformer 71 is controlled, so that the voltage applied to the load 62 can be held constant.
FIG. 10 is a circuit diagram showing a further concrete circuit arrangement of the stabilized power supply circuit shown in FIG. 9. In FIG. 10, those elements and parts similar to those FIG. 9 are indicated by like reference numerals and symbols, and their explanation is omitted. In FIG. 10, reference numeral 80 represents a power supply switch which is inserted so as to perform make-and-break actions of the charge-up path of a capacitor 67 of a trigger circuit B which is intended to actuate a bidirectional thyristor 63. Reference numeral 81 represents a bidirectional thyristor which is inserted so as to trigger, in two step operation, said bidirectional thyristor 63. A rectifying circuit 72 is constructed by a bridge-type rectifying circuit which, in turn, is comprised of four diodes. A detecting circuit 73 is formed with a comparator which, in turn, is composed of bipolar transistors 82 and 83, and is operative so that an output voltage from the rectifying circuit 72 is divided by a voltage-dividing circuit composed of resistors 84 and 85, and the resulting voltage is compared with the voltage derived across a Zener diode 86, and the result of detection is exhibited as a current (amount of light) of a light-emitting diode of a photo-coupler 87 which is inserted in the collector circuit of the transistor 83. A controlling circuit 74 is comprised of the light-emitting diode of said photo-coupler 87 and a photo-transistor, and is operative so that by utilizing its photo-transistor to serve as a variable resistor element 66, so that the value of the resistance of this photo-transistor 66 is adapted to be controlled by the amount of light of said light-emitting diode. Reference numerals 88 and 89 represent a power amplifier and a speaker, serving as a load 62, respectively. | A switching circuit whose current-to-voltage characteristic across a first terminal and a second terminal is a bidirectional and symmetrical breakdown characteristic, and arranged especially so that said breakdown voltage will vary in accordance with the variation of voltage applied to a controlling terminal. Said switching circuit, in case it is used as a trigger circuit for controlling the firing angle of a bidirectional thyristor, unfailingly performs actuation of the bidirectional thyristor without being much affected by such factors as the fluctuations of the power supply frequency and the power supply voltage. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application No. 62/173,745, filed on Jun. 10, 2015, entitled “METHOD, SYSTEM, AND APPARATUS FOR PHYSICIAN STUDY MANAGER,” the entire contents of which are hereby incorporated by reference.
BACKGROUND
[0002] Medical professionals and physicians that work at medical facilities, and the support systems that run those same medical facilities, have traditionally been managed and maintained on-site by the respective medical facility out of which they operate. As such, it typically falls to the medical facility to manage the scheduling of patients and the medical records and procedures associated with those patients, such as tests or testing records of patients, physician-performed diagnostic analyses, physician-generated reports, and patient recommendations. This can be a costly and inefficient burden for the medical facility, and for any medical professionals that may be involved with the procedure.
[0003] Insurance requirements and government regulations have additionally burdened the medical professional community with further records to manage; medical facilities now must manage a patient's referral letters as issued from a primary care doctor, electronic health records, demographics of the patients that have received services, and pharmaceutical and medical device prescriptions. Physicians are often burdened with the time consuming tasks of analyzing vast amounts of patient data and transforming this data into reports that may further require submission to insurance organizations to justify expenditures. The reporting, tracking, scheduling, and management of the day to day operations of a medical facility are an arduous, burdensome process.
[0004] The volume of information, along with the various levels of confidentiality and security required by law, have made it difficult for medical professionals to manage a patient database, or take part in business management processes, cost-effectively and efficiently. Medical professionals need to spend a significant amount of time processing the sheer volume of information that is sent their way, and even more time ensuring that they comply with all applicable legal standards, further burdening a field that is already overstretched. Worse still, such processing is often highly duplicative of work that has already been completed by another medical professional somewhere else, such as a patient's previous physician; this not only means that the patient will waste money and time having physicians performing work that has already been completed, but can mean that when information is shared between medical professionals or medical facilities, substantial efforts must be devoted to separating new and useful patient data from old and duplicative patient data. The management costs and hardships medical professionals experience have additionally burdened patients by increasing the costs of healthcare, and the time required to schedule medical appointments.
[0005] The medical industry, particularly the sleep wellness medical industry, has lacked clear communication between physicians, other medical providers, and insurers. This has hindered the delivery and quality of care that patients receive, slowed insurance claim processing through a lack of communication and coordinated documentation, and hindered payments receivable for physicians, testing facilities, technicians, insurance companies, and durable medical equipment providers.
[0006] These inefficiencies also serve as an obstacle to other reform in the medical industry. A growing topic of interest in the medical industry is “personalized medicine,” a medical model in which treatments are specifically tailored to patients or groups of patients based on the characteristics of the patients or the anticipated responses each patient will have to the treatment. For example, a medical condition of a first patient may be most effectively treated by a first treatment regimen or a particular drug, while the same medical condition in a second patient may be most effectively treated by a somewhat different treatment regimen, or a different drug or combination of drugs. Personalized medical treatments, while typically of greater effectiveness than more standardized medical treatments, rely on accurate information being available about the patient in question and the anticipated responses that the patient will have to a given treatment. The information that is typically required in order to structure a personalized treatment regimen (such as DNA or RNA sequences, or protein levels) is typically fairly difficult to collect and interpret, typically costing upwards of a thousand dollars per patient even in a best-case scenario. Often, because of communication inefficiencies, this information is not effectively used by medical professionals even when it exists, significantly reducing the benefit to the patient of collecting the information in the first place.
SUMMARY
[0007] Accordingly, a comprehensive system directed at assisting physicians in managing the workflow processes of a patient's treatment may be provided. Such a system may improve the efficiency of the medical industry, particularly the sleep wellness portion of the medical industry, by improving communications and transfers of records between healthcare providers, reducing duplicative work, and facilitating the construction of patient medical reports and statistical analytics. Such a system may also improve communications between medical practitioners and health insurance providers, improving claim processing time by making it easier to transmit the appropriate documentation and standardizing documentation submissions. Such a system may also improve communications between medical practitioners and medical equipment providers, streamlining the ordering process and reducing the chances of miscommunication.
[0008] According to an exemplary embodiment, a Physician Study Manager may be a centralized or de-centralized data management system targeted most specifically at the medical industries, such as the sleep medicine and wellness industry. The manager may be administered by a web portal and offered as a software service. Data may be collected from relevant stakeholders of the sleep medicine and wellness industries in coordination with capable medical diagnostic equipment. The manager may improve medical care coordination by automating the workflow of medical processes in addition to improving treatment of a patient through streamlined data visualization and processing, record retainage, and diagnostic reporting. The manager may manage the needs of all parties involved in the diagnosis, treatment, and care of sleep related conditions by providing an unprecedented level of access to patient information. This access may create an integrated sleep wellness database. Patients managed by the Physician Study Manager may be tracked from referral, through treatment, and post treatment. Users may easily generate diagnostic reports, and transmit them to external entities, such as insurance or medical equipment providers, directly from the manager. The Physician Study Manager may sort a patient by their treatment status thereby eliminating the possibility that a particular patient may stagnate in one particular status. The Physician Study Manager may ensure that a patient completes the treatment process and receives effective medical care. The software may feature electronic security measures to protect relevant electronic information. The Physician Study Manager may be HIPPA compliant and feature additional electronic security measures to protect relevant electronic information.
[0009] According to an exemplary embodiment, the Physician Study Manager may have enhanced functionalities that allow a physician to view patient data, such as a sleep assessment performed in a medical facility or by outpatient care. The Physician Study Manager may run as a software as a service platform with a web-portal or natively on the users local computer processor. The Physician Study Manager may further be optimized to run on a local network. The manager may generate an autonomous report based off the data of a patient. The report may additionally be customizable by user defined preferences and edited directly within the report. The manager may also send patient reports and recommendations to other relevant stakeholders such as insurance entities and medical device providers.
[0010] According to an exemplary embodiment, a computer-implemented health data management system may be disclosed. Such a system may include a processor and a memory, and may implement a physician study management portal accessible by a credentialed user from a standard browser. The memory may be arranged to cause the computer to carry out the following steps: receiving, via a Web portal, medical data of a patient; matching, with a processor, the medical data of the patient with a profile of the patient, and associating the medical data and the profile of the patient in the memory; identifying, with a processor, a status indication of the profile of the patient, the status indication providing an indication of the status of one or more medical tests conducted on the patient; when the status indication indicates that at least one of the medical tests conducted on the patient has yet to be interpreted by a physician, identifying, with a processor, a physician of the patient, and displaying, on a display, a medical test result of a patient; receiving, from a user interface, an interpretation of a medical test result; updating, with a processor, the status indication of the profile of the patient; and generating and issuing a report for the patient comprising the medical data of the patient and the interpretation of the medical test result.
[0011] According to another exemplary embodiment, a method for management of medical data may be disclosed. Such a method may include: uploading, from a user interface, to a computer-implemented health data management system having a processor and a memory, medical data of a patient; wherein the health data management system is configured to: match, with the processor of the health data management system, the medical data of the patient with a profile of the patient, and associating the medical data and the profile of the patient in the memory of the health data management system; identify, with the processor, a status indication of the profile of the patient, the status indication providing an indication of the status of one or more medical tests conducted on the patient; and when the status indication indicates that at least one of the medical tests conducted on the patient has yet to be interpreted by a physician, identify, with a processor, a physician of the patient, and displaying, on a display, a medical test result of a patient; wherein the method further includes uploading, from a user interface, to the health data management system, an interpretation of a medical test result; wherein the health data management system is further configured to: update, with the processor, the status indication of the profile of the patient; and generate and issue a report for the patient comprising the medical data of the patient and the interpretation of the medical test result.
[0012] According to another exemplary embodiment, a computer-implemented health data management apparatus may be disclosed. Such an apparatus may include a computer having a processor and a memory and implementing a physician study management utility accessible by a credentialed user from a user interface. The memory may be a non-transitory computer readable medium having code arranged to cause the computer to carry out the following steps: receiving, on the health data management apparatus, from a local network, medical data of a patient; matching, with the processor, the medical data of the patient with a profile of the patient, and associating the medical data and the profile of the patient in the memory; identifying, with the processor, a status indication of the profile of the patient, the status indication providing an indication of the status of one or more medical tests conducted on the patient; when the status indication indicates that at least one of the medical tests conducted on the patient has yet to be interpreted by a physician, identifying, with the processor, a physician of the patient; displaying, on a display of the apparatus, a request for the input of the physician of the patient; authenticating, with the processor, a credential of the physician of the patient; and displaying, on a display of the apparatus, a medical test result of a patient; receiving, from the user interface, an interpretation of a medical test result; updating, with the processor, the status indication of the profile of the patient; generating and issuing a report for the patient comprising the medical data of the patient and the interpretation of the medical test result; and sharing the report on the local network.
BRIEF DESCRIPTION OF THE FIGURES
[0013] Advantages of embodiments of the present invention will be apparent from the following detailed description of the exemplary embodiments. The following detailed description should be considered in conjunction with the accompanying figures in which:
[0014] Exemplary FIG. 1 displays an exemplary embodiment of the Dashboard of a Physician Study Manager;
[0015] Exemplary FIG. 2 displays an exemplary embodiment of the Dashboard of a Physician Study Manager;
[0016] Exemplary FIG. 3 displays an exemplary embodiment of the Dashboard of a Physician Study Manager;
[0017] Exemplary FIG. 4 displays an exemplary embodiment of the Dashboard of a Physician Study Manager;
[0018] Exemplary FIG. 5 displays an exemplary embodiment of the Dashboard of a Physician Study Manager;
[0019] Exemplary FIG. 6 displays an exemplary embodiment of the Dashboard of a Physician Study Manager;
[0020] Exemplary FIG. 7 displays an exemplary embodiment of a report generated by a Physician Study Manager;
[0021] Exemplary FIG. 8 displays an exemplary embodiment of a report generated by a Physician Study Manager;
[0022] Exemplary FIG. 9 displays an exemplary embodiment of a report generated by a Physician Study Manager;
[0023] Exemplary FIG. 10 displays an exemplary embodiment of a report generated by a Physician Study Manager;
[0024] Exemplary FIG. 11 displays an exemplary embodiment of a report generated by a Physician Study Manager;
[0025] Exemplary FIG. 12 displays an exemplary embodiment of a report generated by a Physician Study Manager;
[0026] Exemplary FIG. 13 displays an exemplary embodiment of a preferences utility of a Physician Study Manager;
[0027] Exemplary FIG. 14 displays an exemplary embodiment of a preferences utility of a Physician Study Manager;
[0028] Exemplary FIG. 15 displays an exemplary embodiment of a preferences utility of a Physician Study Manager;
[0029] Exemplary FIG. 16 displays an exemplary embodiment of a threshold selection utility of a Physician Study Manager;
[0030] Exemplary FIG. 17 displays an exemplary embodiment of a threshold selection utility of a Physician Study Manager;
[0031] Exemplary FIG. 18 displays an exemplary embodiment of an impressions utility of a Physician Study Manager;
[0032] Exemplary FIG. 19 displays an exemplary embodiment of a Durable Medical Equipment selection and order utility of a Physician Study Manager;
[0033] Exemplary FIG. 20 displays an exemplary embodiment of a Durable Medical Equipment selection and order utility of a Physician Study Manager;
[0034] Exemplary FIG. 21 displays an exemplary embodiment of a Durable Medical Equipment selection and order utility of a Physician Study Manager;
[0035] Exemplary FIG. 22 displays an exemplary embodiment of a statistical analysis utility of a Physician Study Manager;
[0036] Exemplary FIG. 23 displays an exemplary embodiment of a statistical analysis utility of a Physician Study Manager;
[0037] Exemplary FIG. 24 displays an exemplary embodiment of a statistical analysis utility of a Physician Study Manager;
[0038] Exemplary FIG. 25 displays an exemplary embodiment and features of a notes utility of a Physician Study Manager;
[0039] Exemplary FIG. 26 displays an exemplary embodiment of an algorithms utility of a Physician Study Manager.
DETAILED DESCRIPTION
[0040] Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention. Further, to facilitate an understanding of the description discussion of several terms used herein follows.
[0041] As used herein, the word “exemplary” means “serving as an example, instance or illustration.” The embodiments described herein are not limiting, but rather are exemplary only. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the terms “embodiments of the invention”, “embodiments” or “invention” do not require that all embodiments of the invention include the discussed feature, advantage or mode of operation.
[0042] Further, many of the embodiments described herein may be described in terms of sequences of actions to be performed by, for example, elements of a computing device. It should be recognized by those skilled in the art that the various sequence of actions described herein may be performed by specific circuits (e.g., application specific integrated circuits (ASICs)) and/or by program instructions executed by at least one processor. Additionally, the sequence of actions described herein can be embodied entirely within any form of computer-readable storage medium such that execution of the sequence of actions enables the processor to perform the functionality described herein. Thus, the various aspects of the present invention may be embodied in a number of different forms, all of which have been contemplated to be within the scope of the claimed subject matter. In addition, for each of the embodiments described herein, the corresponding form of any such embodiments may be described herein as, for example, “a computer configured to” perform the described action.
[0043] In an exemplary embodiment, the Physician Study Manager may function as a comprehensive medical workflow management system. The Physician Study Manager may operate as a platform for the diagnosis and treatment of a patient, for example within any medical field or medical sub-field, or within any other field involving customized treatment. The Physician Study Manager may also be a manager of a larger medical workflow process or software as a service product.
[0044] In an exemplary embodiment, a Physician Study Manager may be accessible by a web browser through an online portal, or through such other method of access as may be desired. In an embodiment, the Physician Study Manager may be remotely accessible from a plurality of computers, or from any properly configured computer, at any time. A user of the Physician Study Manager, such as a physician or medical professional or other authorized party, may have a unique username and a password that may be used to grant access to the system. Additionally, several physicians may operate the Physician Study Manager with a larger network of medical care providers. A specific physician may have a unique log-in id associated with a set of preferences, such that certain preferences may be custom-tailored to a specific physician. In an exemplary embodiment, other parties or devices may have access, or may have more limited access, to a Physician Study Manager; for example, in an exemplary embodiment, a technician, capable medical assessment device, or other entity may upload data related to a patient to the Physician Study Manager over a web portal. The data may be identified to a unique patient and may contain information, such as medical reports or other raw data (such as, for example, a sleep report) concerning the patient that may assist in diagnosing the patient. The data may be uploaded to the Physician Study Manager web portal or may be maintained locally on a user's computer. In an exemplary embodiment, a Physician Study Manager may additionally have full functionality on a singular computer that is not connected to a web portal, or may be fully functional on a local network. Users of the Physician Study Manager may generate and preview medical reports (such as sleep reports), raw data, or other information for each patient. The Physician Study Manager may additionally organize relevant video which may be viewed through the Physician Study Manager or when directly connected to a local network (such as a local network of a sleep center).
[0045] The Physician Study Manager may further allow users to view patient charts, which may include, for example, specific study reports, questionnaires, and documents corresponding to a particular patient. In an exemplary embodiment, the physician study manager may also be configured to extract data from patient charts and other documents, such as clinical reports that have been provided by other physicians or other sources and which provide data in a less than optimally usable form. For example, in an exemplary embodiment, a Physician Study Manager may perform quantitative data extraction (QDE) on a set of sleep physiological data, by running a QDE method on the data. This method may automatically extract quantitative data values from clinical reports or from other similar sources as may be desired. In an exemplary embodiment, a QDE process may run in the background of the Physician Study Manager interface, allowing a user to make use of the Physician Study Manager user interface while a QDE process is being run.
[0046] In an exemplary embodiment, a QDE process that may be operated in order to extract quantitative data from clinical reports or other documents may be device-agnostic. In an exemplary embodiment, such a process may be run on any computing device, or any computing device that may operate the Physician Study Manager user interface, as desired. In another exemplary embodiment, a user may be able to perform the QDE process on another machine not running the Physician Study Manager or the Physician Study Manager user interface; for example, in an exemplary embodiment, a medical services provider may designate one or more computers on a network to perform the QDE process in order to reduce hardware requirements of other computers on the network, if desired. Data extracted by the QDE process may be stored, for example in the Physician Study Manager or in a form accessible to the Physician Study Manager, as desired.
[0047] In an exemplary embodiment, charts and documents belonging to patients or otherwise associated with the Physician Study Manager may be sorted by a folder view, with parent folders and subfolders organized in a hierarchical manner. The documents may be displayed within the Physician Study Manager or the documents may be exported from the Physician Study Manager in a relevant or desired electronic or paper format.
[0048] Referring generally to FIGS. 1-6 , an exemplary embodiment of a Physician Study Manager may be shown. In an exemplary embodiment, the Physician Study Manager may display a virtual dashboard when a user first accesses the system. As shown in, for example, FIG. 3 , the dashboard may show a list of patients who have profiles in the system. The list of patients may display data associated with a list of patients; for example, an exemplary entry for a patient 302 may include information such as, but not limited to, the name of the patient, date of birth, referral type or other referral information (such as a name of a referring physician), an acquisition number and/or acquisition date (for example, the date that the patient was acquired as a client), an appointment type (which may include, for example a requested and an ordered appointment type), and a technician assigned to the patient. An exemplary entry for a patient 302 may also include a “scored by” section indicating one or more technicians or physicians who performed a medical test on the patient (such as, for example, generating an Apnea-Hypopnea Index (AHI) score for the patient), a “report prepared by” section indicating one or more parties who generated a report on a medical condition of the patient, a referring physician, an interpreting physician, a primary physician, the patient's insurance type, a number of pending days until the patient's next appointment, the status of the patient or of any tests requested to be run on the patient (for example, if an AHI score has been requested for the patient, if the patient's test results have yet to be interpreted, the patient's status may be “interpretation in progress,” and if the patient's test results have been interpreted already, the patient's status may be “scoring completed”), or any other indicators, as desired. In another embodiment, other information, such as a location of a clinic treating or referring the patient, any other information about an acquisition or appointment of the patient, or any other technician information may also be stored.
[0049] As shown in exemplary FIG. 6 , the dashboard may additionally have an advanced patient search option 602 that may allow a user to search through the patient database by a name of a patient or other customizable search parameters. Additionally, the advanced patient search option 602 may allow for filtering by relevant criteria such as, but not limited to, the following: the patient name, a range of dates, a single date, a patient status, and a facility or location.
[0050] In an exemplary embodiment, for example as shown in FIG. 3 , a dashboard may display a status indication of a patient 304 and sort patients by their status. The status of a patient's file may be indicated by a status indication 304 , and patients' files may be marked as, for example, having an interpretation pending, having a finalized report, having a rejected data set or study, and other relevant status indications 304 of a last completed step of a patient in the workflow process. The status indications 304 may further be customizable to include any desired additional options or remove any desired aforementioned options. The user may additionally save a unique view or representation of the dashboard as the default view of the dashboard. The dashboard may initially have a default view in which patients are sorted by status.
[0051] Referring generally to FIGS. 7-12 , an exemplary embodiment of a Physician Study Manager may be shown. In an exemplary embodiment, a Physician Study Manager may generate and issue a report for a patient. The report may be generated automatically or manually. The report may include the results of a statistical analysis of the data file of a patient. The report may display relevant patient information including, but not limited to, the following: the patient's identifying information (such as first and last name), the patient's demographic information (such as the patient's age), the technician that performed the study, the physician that interpreted the results, the patient's referring and primary care physicians, the patient's body mass index, the patient's weight, the specific type of study conducted, the types of diagnostic techniques and equipment used, technical comments from the technician, the patient's sleep architecture, the patient's respiratory parameters, the patient's leg movement data, the patient's cardiac data and impressions, and the patient's Epworth score.
[0052] The report may further be customizable to include any desired additional options or remove any desired aforementioned options. The report may be edited directly, or may, for example, be edited by an alternate tab, such as the alternate tab shown in exemplary FIG. 9 , that may allow a user to navigate the report with additional features. The tab to edit the features may be utilized to freely manipulate text within report fields such as but not limited to the following: impressions, diagnostic information, and recommendations. The report may additionally feature drop down menus, checkboxes, radio buttons, or other electronic elements that may be toggled to assist with the population of relevant information into the report. When one of the aforementioned elements is toggled it may prepopulate data. The specific sections of the report may appear in any unique order or combination that a physician may prefer, and may be accompanied by any other relevant information; for example, in at least one exemplary embodiment, the technician's notes and the patient's full diagnostic PSG report may be included along with the selected sections of the report. A physician may desire to review the diagnostic report to check for data abnormalities or data points of interest.
[0053] Referring generally to FIGS. 13-15 , an exemplary embodiment of a Physician Study Manager may be shown. According to an exemplary embodiment, a Physician Study Manager may provide a user with the ability to tailor a report to the specific preferences of the user. Preferences may be saved as, for example, a global setting, or may be set for each of several unique study types. For example, according to an exemplary embodiment, study types may include studies of adult and pediatric patients, each of which may have different preferences associated with them. The preferences may include information pertaining to but not limited to the following: the layout configuration of the report, clinical information relating to the patient, indications, medications, sleep study techniques, technical comments, sleep architecture, respiratory parameters, leg movement data, cardiac data, impressions, and diagnosis recommendations. As shown in exemplary FIG. 14 , other information may be added by default, for example identifying and demographic information about the patient or an identification of the interpreting physician. The preferences may further be customizable to include additional options or remove aforementioned options.
[0054] Referring generally to FIGS. 16-17 , an exemplary embodiment of a Physician Study Manager may be shown. In an exemplary embodiment of the Physician Study Manager, physicians may set customizable thresholds in the Physician Study Manager that may allow reports to be automatically generated with specifically relevant and customizable information. In an exemplary embodiment, a Physician Study Manager may have more than one set of thresholds that can be set. For example, exemplary FIG. 16 may show a utility in which a physician can set a number of thresholds having to do with a patient's sleep architecture; for example, a physician may set a threshold for each of several tiers of a patient's arousal index, with an arousal index of five or less indicating an insignificant amount of sleep disruption, an arousal index between 5 and 25 indicating a mild amount of sleep disruption, an arousal index of between 25 and 50 indicating a moderate amount of sleep disruption, and an arousal index of above 50 indicating a severe amount of sleep disruption. Exemplary FIG. 17 may show similar thresholds for a patient's respiratory parameters; other thresholds may be set for other test parameters, as desired. These thresholds may save the physician time, increase the accuracy of reporting, and eliminate significant amounts of repetitive editing.
[0055] In an exemplary embodiment, threshold values may be used in conjunction with other rules. For example, according to an exemplary embodiment, a Physician Study Manager may perform rule-based auto-tagging of patient data or data sets, based on threshold values (which may be globally set or set for a particular patient, as desired) and based on a patient's physiological data. This may allow for quick segmentation of studies and tasks, saving time. For example, in an exemplary embodiment, a particular user-specific threshold for a particular patient may be set, and the Physician Study Manager may then tag all of the patient's data that represents a value that is outside of that threshold. The Physician Study Manager may then allow tagged portions of a patient's data to be specifically browsable and selectable, highlighting data regions of greatest interest and saving physician time.
[0056] In an exemplary embodiment, physicians may be able to freely text edit the tabular and narrative sections of the report natively within the Physician Study Manager. The section layouts of the report may additionally be modified to display, in a user defined order, the various sections of the report. Accordingly, the report may be highly customized to any desired preferences of a physician. The physician may electronically sign and verify the report to authenticate it. The signature may be time and date stamped. A user may edit the pertinent thresholds of the sleep architecture, and respiratory parameters of a diagnostic test to assist the physician in determining an accurate diagnoses. The criteria relevant to a patient's sleep architecture may include, for example, the patient's sleep efficiency, primary sleep latency, REM latency, slow wave latency, and arousal index. Criteria relevant to a patient's respiratory index may include, for example, the patient's oxygen saturation, the patient's optimal titration value, the patient's Auto PAP, the patient's UARS, the patient's OSA, or the patient's CSA, or any other criteria, as desired. These thresholds may be input by a percentage, ratio, fixed amount, or other relevant criteria. In some exemplary embodiments, these thresholds may indicate normal, reduced, or markedly reduced information. Additionally, thresholds for insignificant, mild, moderate, and severe percentages may be user defined.
[0057] Referring generally to FIG. 18 , an exemplary embodiment of a Physician Study Manager may be shown. In an exemplary embodiment of the Physician Study Manager, a user may configure impression statements 1802 , such as those shown, in order to eliminate redundant typing. In an exemplary embodiment, the Physician Study Manager may save and store pre-typed text that may be used to pre-populate specific sections. The text may be recalled as a default input for an impression. Configurable impressions may include, but are not limited to, the following: OSA optimal and sub-optimal titration, sleep architecture, sleep efficiency, primary sleep latency, REM latency, and slow wave latency, central sleep apnea, periodic limb movements during sleep, oxygen destructions during sleep, supplemental oxygen, associated arousals, alpha intrusion, and cardiac abnormalities. Additionally, a user may add any desired custom impressions. Adding or removing an impression from a report may be accomplished by, for example, drop down menus, checkboxes, radio buttons, or other electronic elements that may be toggled such that when selected will display or remove the text of the impression. The electronic elements of the programmable impressions may greatly save the physician time, eliminate repetitive typing and redundancy. Furthermore, it may increase the accuracy of the report.
[0058] Referring generally to FIGS. 19-20 , an exemplary embodiment of a Physician Study Manager may be shown. An exemplary embodiment of a Physician Study Manager may include a utility allowing a request for durable medical equipment to be made; in an exemplary embodiment, a request for durable medical equipment may be made in a field of entry within the Physician Study Manager, or through another utility, as desired.
[0059] In an embodiment, in order to request durable medical equipment, a user may open an order for durable medical equipment for a patient, and may then be able to add or edit information on an order form. In an exemplary embodiment, an order form may feature drop down menus, checkboxes, radio buttons, or other electronic elements that may be toggled in order to add or edit information or edit the placement of information. Information in the order form may be organized into a first group of sections, such as a section covering order info (such as the type and date of the order), a diagnosis section, a section providing details about the machine or other article of durable medical equipment to be ordered, and additional notes/comments and recommendations of any user. The first group of sections may be customizable to contain additional sections. The sections may include drop down menus, checkboxes, radio buttons, or other electronic elements that may further contain customizable inputs. The order info section may include drop down menus, checkboxes, radio buttons, or other electronic elements in which a user may be able to specify certain information relevant to the order, such as the order type, ordering date, length of need, the durable medical equipment provider, or the ordering physician. The diagnosis section may include drop down menus, checkboxes, radio buttons, or other electronic elements, and may allow a user to specify a diagnosis of the patient, such as obstructive sleep apnea, periodic limb movement syndrome, bruxism, pathologic sleepiness, central sleep apnea, primary snoring, nocturnal, hypoxemia, idiopathic hypersomnia, upper airway resistance syndrome, REM behavior disorder, normal study, or narcolepsy, which may be relevant to the order. The machine details section may include drop down menus, checkboxes, radio buttons, or other electronic elements by which a user may specify, for example, certain attributes of an article of durable medical equipment to be ordered, including the device type, pressure, ramp time, humidifiers, monitoring device, type of mask that should be used in the device, and type of tubing that should be used. A user may also be able to specify one or more additional items that may be included with the article, such as, for example, an oral or mouth cushion for combination mask, full face cushions, a nasal pillow, a chinstrap, disposable filter, a nasal pillow for a combination mask, a nasal cushion, headgear, a water chamber, and a non-disposable filter, or any other items as may be desired.
[0060] Referring generally to FIG. 21 , an exemplary embodiment of a Physician Study Manager may be shown. In an exemplary embodiment, a Physician Study Manager may provide a utility in which a user may open a request for durable medical equipment; durable medical equipment may include, for example, sleep assistive devices and sleep assessment devices for testing. In an exemplary embodiment, a Physician Study Manager may offer different permissions to a user based on the user's credentials and authority; for example, in an exemplary embodiment, a Physician Study Manager may allow a technician to prepare a request, but may require a physician to approve the request before the request is communicated. The request may optionally originate from the physician or an alternate designated user of the Physician Study Manager for approval of an external entity; for example, in an exemplary embodiment, a request may be shared directly with an insurance company that may provide for full or partial fund re-imbursement of the medical equipment. The request may be shared directly with a durable medical equipment provider as an order form and authorization. The requests may be sent to a physician for approval electronically or it may be printed and mailed or faxed.
[0061] Referring generally to FIGS. 22-24 , an exemplary embodiment of a Physician Study Manager may be shown. In an exemplary embodiment, a Physician Study Manager may be configured to perform statistical analysis on information available to it; for example, in an exemplary embodiment, a Physician Study Manager may perform a statistical analysis of the patient's information. In an exemplary embodiment, the analysis portion of the management system may be configured to perform any of a variety of statistical functions such as sorting of the data, normalization, best fit, averaging, and other common statistical analysis methods known in the art. The Physician Study Manager may additionally perform other statistical manipulations, and may be configured to, for example, display all patient information that has been generated within the last 90 days, display all patient information from within the last 30 days, display all patient information within a customizable range of dates, display the best patient data within a range of days, show the AHI values, and Leak Values.
[0062] Referring generally to FIG. 25 , an exemplary embodiment of a Physician Study Manager may be shown. In an exemplary embodiment of a Physician Study Manager, a Physician Study Manager may allow users to input notes directly to a patient's data file. In an embodiment, the note section of a data file may be separate from the traditional note section of a patient's chart. In some exemplary embodiments, these notes may be kept separate from medical administrators, schedulers, and other support staff and may be recorded by the technician for the physician, or they may be recorded by the physician for the technician. The notes may feature other security elements; for example, in some exemplary embodiments, viewing of the notes may be restricted to parties with some credential, and may be, for example, password protected or permission based, or may be otherwise protected by another method desired or known in the art. In such an embodiment, the customizable security checks of the notes may prevent unauthorized entities from viewing the text of the notes. The notes may additionally be useful for, and may be provided to, other outside medical entities or insurance agencies. Universal notes may also be utilized that feature minimal security checks in the event that the text is intended for schedulers, support staff, and other relevant entities' on a non-secured basis.
[0063] Referring generally to FIG. 26 , an exemplary embodiment of a Physician Study Manager may be shown. In an exemplary embodiment of a Physician Study Manager the Physician Study Manager may use programmable algorithms to insert the appropriate diagnoses, impressions, and recommendations into a report. The algorithms may represent an intelligent computer implemented method in which all desired data, and its relevant derivatives, are assembled into a comprehensive report. The report may be tailored to be brief in nature or thorough dependent on the user defined inputs. The algorithms may draw upon variables such as user defined parameters, industry standard parameters, other parameters established by the Physician Study Manager, and other variables contained within the broader Physician Study Manager network. The algorithms may further perform a series of steps according to user defined conditional statements. These conditional statements may be represented by an if/then statement that a user of the Physician Study Manager may provide. The algorithms may be established by unique preferences of a user such that the algorithm is capable of compiling the appropriate diagnoses, impressions, and recommendations on the final reports. The algorithms can assist in the automation of the report generation. An input may be the statistical features and analysis of the Physician Study Manager or an input may be a physician established threshold or groups of thresholds. The inputs may be established by industry standards or other default parameters in combination with user defined parameters. The Physician Study Manager may compare input parameters such as Titration Sub Optimality, Bruxism, Alpha Intrusion, Cardiac Abnormalities, and BMI from a patients data file to the physician established thresholds. In at least one exemplary embodiment, if the thresholds are exceeded a pre-populated message may be inserted into the report. Examples of the aforementioned inputs are meant to be illustrative rather than restrictive.
[0064] In some exemplary embodiments, the algorithm may refer to an ability of the Physician Study Manager to utilize rule based insertion of custom sentences into the report, depending on the clinical metrics obtained from the sleep study. As an example, a physician may configure: If AHI<5: “Patient is normal. As an example, a physician may configure: If AHI>=5 and AHI<15: “Patient has mild sleep apnea.” As an example, a physician may configure: If AHI>=15 and AHI<30: “Patient has moderate sleep apnea.” As an example, a physician may configure: If AHI>=30: “Patient has severe sleep apnea.” Because the thresholds are customizable, another physician may set different thresholds for the AHI, thereby allowing the algorithm to pre-populate data at different thresholds for the same diagnoses. The Physician Study Manager may additionally utilize several if/then conditional statements that may be configured by the physician in the Physician Study Manager to insert custom diagnosis/comments in the final interpretation report. Examples, of the aforementioned thresholds are meant to be illustrative rather than restrictive.
[0065] The foregoing description and accompanying figures illustrate the principles, preferred embodiments and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art.
[0066] Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments may be made by those skilled in the art without departing from the scope of the invention as defined by the following claims. | A Physician Study Manager may be a centralized or de-centralized data management system for medical industries, such as the sleep medicine and wellness industry. The manager may be administered by a web portal and offered as a software service. Data may be collected from relevant stakeholders of the sleep medicine and wellness industries in coordination with capable medical diagnostic equipment. The manager may improve medical care coordination by automating the workflow of medical processes in addition to improving a patient's treatment through streamlined data visualization and processing, record retainage, and diagnostic reporting. The manager may manage the needs of everyone involved in the diagnosis, treatment, and care of sleep related conditions by providing access to patient information. Users may generate diagnostic and therapy reports, and transmit them to external entities, such as insurance or medical equipment providers, directly from the manager. The software may feature electronic security measures. | 6 |
FIELD OF THE INVENTION
[0001] This invention pertains to certain novel red colorant compounds which contain one or more ethylenically-unsaturated (vinyl), photopolymerizable radicals that may be copolymerized (or cured) with ethylenically-unsaturated monomers to produce colored compositions such as colored acrylic polymers, e.g., polymers produced from acrylate and methacrylate esters, colored polystyrenes, and similar colored polymeric materials derived from other ethylenically-unsaturated monomers. The novel colorant compounds possess good fastness (stability) to ultraviolet (UV) light, good solubility in vinyl monomers and good color strength. The present invention also pertains to processes for preparing certain of the photopolymerizable colorant compounds. The ethylenically unsaturated colorant compounds may be suitable for use in coatings that are applied to wood, glass, metal, thermoplastics and the like.
BACKGROUND
[0002] Colored polymeric materials may be produced by combining a reactive polymer, such terepolymers having epoxy groups or polyacryloyl chloride, with anthraquinone dyes containing nucleophilic reactive groups such as amino or hydroxy groups. Similarly, acryloylaminoanthraquinone dyes may be grafted to the backbone of vinyl or divinyl polymers. Likewise, anthraquinone dyes containing certain olefinic groups have been polymerized to produce polymeric dyes/pigments. (See, e.g., J.S.D.C., April 1977, pp 114-125).
[0003] U.S. Pat. No. 4,115,056 describes the preparation of blue, substituted 1,4-diaminoanthraquinone dyes containing one acryloyloxy group and the use of the dyes in coloring various fibers, especially polyamide fibers. U.S. Pat. No. 4,943,617 discloses liquid crystalline copolymers containing certain blue, substituted 1,5-diamino-4,8-dihydroxyanthraquinone dyes containing an olefinic group copolymerized therein to provide liquid crystal copolymers having high dichromism. U.S. Pat. No. 5,055,602 describes the preparation of certain substituted 1,4-diaminoanthraquinone dyes containing polymerizable acryloyl and methacryloyl groups and their use in coloring polyacrylate contact lens materials by copolymerizing.
[0004] U.S. Pat. No. 5,362,812 discloses the conversion of a variety of dye classes, including anthraquinones, into polymeric dyes by (a) polymerizing 2-alkenylazlactones and reacting the polymer with dyes containing nucleophilic groups and by (b) reacting a nucleophilic dye with an alkenylazlactone and then polymerizing the free radically polymerizable dyes thus produced. The polymeric dyes are reported to be useful for photoresist systems and for color proofing. U.S. Pat. No. 5,367,039 discloses a process for preparing colored vinyl polymers suitable for inks, paints, toners and the like by emulsion polymerization of a vinyl monomer with reactive anthraquinone dyes prepared by functionalizing certain anthraquinone dyes with methacryloyl groups.
[0005] The preparation of a variety of dyes, including some anthraquinones, that contain photopolymerizable groups and their use for color filters suitable for use in liquid crystal television sets, color copying machines, photosensitive resist resin compositions, and the like are described in U.S. Pat. No. 5,578,419. The preparation of a variety of anthraquinones dyes which contain photopolymerizable groups are disclosed in U.S. Patent application 20020068725. U.S. Pat. No. 5,900,445 discloses erasable ink compositions containing certain magenta 1-amino,4-hydroxy anthraquinones that are substituted in the 2 position with either thio or amino groups that contain photopolymerizable groups.
[0006] The present invention provides economical, photopolymerizable red anthraquinone colorants with improved light stability and solubility in solvents or monomers relative to that known in the art.
SUMMARY OF THE INVENTION
[0007] This invention relates to ethylenically unsaturated, photopolymerizable or free radically polymerizable, red anthraquinone colorants of Formula I:
wherein:
R is a divalent linking group selected from the group consisting of —C 2 -C 8 -alkylene-, —(C 2 -C 4 -alkylene-Z) n —C 2 -C 4 -alkylene-, —C 2 -C 6 -alkylene-O-arylene-C 2 -C 6 -alkylene-, -arylene-O—C 1 -C 6 -alkylene-, —CH 2 -1,4-cyclohexylene-CH 2 — and -arylene-C 1 -C 6 -alkylene-; Z is —O—, —S—, —N(SO 2 R 4 )—, —N(R 3 )CO— or —N(COR 5 )—; R 1 is hydroxy, —NHSO 2 R 2 or NHCOR 2 ; R 2 is C 1 -C 6 -alkyl, C 3 -C 8 -cycloalkyl or aryl; Y is —O—or —N(R 3 )—; R 3 is hydrogen, C 1 -C 6 -alkyl, C 3 -C 8 -cycloalkyl or aryl; R 4 is C 1 -C 6 -alkyl, C 3 -C 8 -cycloalkyl or aryl; R 5 is C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 3 -C 8 -cycloalkyl or aryl; n is an integer from 1 to 3; and Q is an ethylenically unsaturated, photopolymerizable or free radical initiated polymerizable group.
[0019] The present invention also relates to a process for making concentrated solutions of the ethylenically-unsaturated photopolymerizable colorants (e.g., dyes) wherein toluene, methylethyl ketone, acetone, hexanediol diacrylate, tri(propyleneglycol) diacrylate and the like are preferred solvents. The concentration of dye in the solution can be from about 0.5 weight percent (wt %) to about 40 wt %.
[0020] The present invention further relates to a coating composition containing the photopolymerizable colorants of Formula I. Preferred coating substrates are thermoplastics, glass, wood, paper, metal and the like, particularly preferred thermoplastics are polyesters, acrylics and polycarbonate.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The colorants of the present invention are red. Thus, this invention relates to ethylenically unsaturated, photopolymerizable or free radically polymerizable, red anthraquinone colorants of Formula I:
wherein:
R is a divalent linking group selected from the group consisting of —C 2 -C 8 -alkylene-, —(C 2 -C 4 -alkylene-Z) n —C 2 -C 4 -alkylene-, —C 2 -C 6 -alkylene-O-arylene-O—C 2 -C 6 -alkylene-, -arylene-O—C 1 —C 6 -alkylene-, —CH 2 -1,4-cyclohexylene-CH 2 — and -arylene-C 1 -C 6 -alkylene-; Z is —O—, —S—, —N(SO 2 R 4 )—, —N(R 3 )CO— or —N(COR 5 )—; R 1 is hydroxy, —NHSO 2 R 2 or NHCOR 2 ; R 2 is C 1 -C 6 -alkyl, C 3 -C 8 -cycloalkyl or aryl; Y is —O— or —N(R 3 )—; R 3 is hydrogen, C 1 -C 6 -alkyl, C 3 -C 8 -cycloalkyl or aryl; R 4 is C 1 -C 6 -alkyl, C 3 -C 8 -cycloalkyl or aryl; R 5 is C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 3 -C 8 -cycloalkyl or aryl; n is an integer from 1 to 3; and Q is an ethylenically unsaturated, photopolymerizable or free radical initiated polymerizable group.
[0033] The phrase “ethylenically-unsaturated photopolymerizable group” and/or “free radical initiated polymerizable group” will be understood to the person of skill in the art to refer to a moiety having a reactive C═C double bond, including those having a vinyl group; preferably, the reactive double bond is activated by being attached to an aryl group or an electron withdrawing group such as a carbonyl. The phrase “reactive C═C double bonds” does not include the endocyclic conjugated double bonds in an aromatic ring since these bonds are know to be unreactive to free radical polymerization under normal polymerization conditions.
[0034] Preferred Q groups include the following organic radicals 1-10:
wherein:
R 6 is hydrogen or C 1 -C 6 -alkyl; R 7 is hydrogen; C 1 -C 6 -alkyl; phenyl; phenyl substituted with one or more groups selected from the group consisting of C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, —N(C 1 -C 6 -alkyl), nitro, cyano, C 1 -C 6 -alkoxycarbonyl, C 1 -C 6 -alkanoyloxy and halogen; 1- or 2-naphthyl; 1- or 2-naphthyl substituted with C 1 -C 6 -alkyl or C 1 -C 6 -alkoxy; 2- or 3-thienyl; 2- or 3-thienyl substituted with C 1 -C 6 -alkyl or halogen; 2- or 3-furyl; or 2- or 3-furyl substituted with C 1 -C 6 -alkyl; R 8 and R 9 are, independently, hydrogen, C 1 -C 6 -alkyl, or aryl; or R 8 and R 9 may be combined to represent a —[—CH 2 —] 3-5 — radical; R 10 is hydrogen, C 1 -C 6 -alkyl, C 3 -C 8 -alkenyl, C 3 -C 8 -cycloalkyl or aryl; and R 11 is hydrogen, C 1 -C 6 -alkyl or aryl.
[0041] The term “C 1 -C 6 -alkyl” is used herein to denote a straight or branched chain, saturated aliphatic hydrocarbon radical containing one to six carbon atoms and these radicals optionally substituted with one or two groups selected from hydroxy, halogen, cyano, aryl, aryloxy, arylthio, C 1 -C 6 alkylthio, C 3 -C 8 -cycloalkyl, C 1 -C 6 -alkanoyloxy and —Y—Q. The term “C 3 -C 8 -cycloalkyl” is used to denote a saturated, carbocyclic hydrocarbon radical having three to eight carbon atoms, optionally substituted with at least one C 1 -C 6 -alkyl group(s). The term “aryl” as used herein denotes phenyl and phenyl substituted with one to three substituents selected from C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy and halogen. The terms “C 1 -C 6 -alkoxy”, “C 1 -C 6 -alkoxycarbonyl” and “C 1 -C 6 -alkanoyloxy” are used to denote radicals corresponding to the structures —OR 12 , —CO 2 R 12 and —OCOR 12 , wherein R 12 is a C 1 -C 6 -alkyl group. The term “C 3 -C 8 -alkenyl” is used to denote a hydrocarbon radical having three to eight carbons, straight or branched chained, and that contains at least one carbon-carbon double bond. The term “halogen” is used to include fluorine, chlorine, bromine, and iodine. The terms “C 2 -C 8 -alkylene” and “C 2 -C 4 -alkylene” are used to denote divalent, straight or branched chain hydrocarbon radicals containing two to eight and two to four carbons, respectively, and these groups optionally substituted with hydroxy, halogen, aryl, aryloxy, C 1 -C 6 -alkoxy and —Y—Q. The term “C 1 -C 6 -alkylene” is used to denote a divalent, straight or branched chain, hydrocarbon radicals containing one to six carbons. The term “arylene” as used herein denotes includes 1,2-, 1,3- and 1,4-phenylene and such divalent radicals optionally substituted with C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy or halogen.
[0042] The skilled artisan will understand that each of the references herein to groups or moieties having a stated range of carbon atoms, such as “C 1 -C 6 -alkyl,” includes not only the C 1 group (methyl) and C 6 group (hexyl) end points, but also each of the corresponding individual C 2 , C 3 , C 4 and C 5 groups. In addition, it will be understood that each of the individual points within a stated range of carbon atoms may be further combined to describe subranges that are inherently within the stated overall range. For example, the term “C 3 -C 8 -cycloalkyl” includes not only the individual cyclic moieties C 3 through C 8 , but also contemplates subranges such as “C 4 -C 6 -C 1 cycloalkyl.”
[0043] Preferred embodiments of the present invention include colorants of Formula I where Q, is a group having the formula —COC(R 6 )═CH 2 or
where R 6 is hydrogen or methyl.
[0045] Further preferred embodiments of the present invention are colorants of Formula I wherein R is —C 2 -C 6 -alkylene-, —C 2 -C 4 -alkylene-O-arylene-O—C 2 -C 4 -alkylene-, —(C 2 H 4 O) n —C 2 H 4 — or —CH 2 —1,4-cyclohexylene-CH 2 —; n is an integer selected from 1 to 3; R 1 is hydroxy or —NHSO 2 R 2 ; Y is oxygen and Q is
wherein R 6 is hydrogen or methyl; and R 8 and R 9 are methyl. More preferred are colorants of Formula I where R is —C 2 -C 6 -alkylene-, —C 2 -C 4 -alkylene-O-arylene-O—C 2 -C 4 -alkylene-, —(C 2 H 4 O) n —C 2 H 4 — or —CH 2 -1,4-cyclohexylene-CH 2 —; n is an integer from 1 to 3; R 1 is hydroxy or —NHSO 2 R 2 ; Y is oxygen and Q is —COC(R 6 )═CH—R 7 wherein R 6 is hydrogen or methyl; and R 7 is hydrogen.
[0047] The ethylenically unsaturated (e.g., vinyl functionalized) red colorants of Formula I may be prepared by reacting hydroxy or amino substituted intermediate compounds of Formula II
with the acylating or alkylating agents 1′ through 10′ , as follows:
wherein R 6 , R 7 , R 8 , R 9 and R 11 are as defined above.
[0050] Compounds of Formula II, above, wherein Y is —O— or —N(R 3 )— are known to be useful as disperse dyes and may be prepared by procedures known to those of skill in the art. See, e.g., U.S. Pat. Nos. : 2,640,062; 2,773,071; 3,072,683; 3,324,150; 3,445,485; 3,467,681; 3,530,150; 3,642,835; 3,694,467; 3,769,305; 3,822,992; 3,963,763 and 4,110,072.
EXAMPLES
[0051] The red anthraquinone colorant compounds provided by the present invention are further illustrated by the following examples:
Example 1
[0052] A mixture of 1-amino-4-hydroxy-2-(2′-hydroxyethoxy)anthraquinone (1.12 g, 0.00375 m, C.I. Disperse Red 55 dry cake), 3-isopropenyl-α,α-dimethylbenzyl isocyanate (0.8 g, 0.00375 m), toluene (35 mL) and dibutyltin dilaurate (3 drops) was heated and stirred at 90° C. for about 2 h. The reaction mixture was drowned into heptane (200 mL) with stirring and the red solid was collected by vacuum filtration, washed with heptane and dried in air. The yield of product was quantitative. Field desorption mass spectrometry (FDMS) supported the following structure:
[0053] An absorption maximum at 516 nm (extinction coefficient=2.95×10 4 ) was observed in the UV-visible absorption spectrum in N,N-dimethylformamide (DMF) solvent.
Example 2
[0054] A mixture of 1-amino-4-hydroxy-2-[2′-[4′-(2′-hydroxyethoxy)phenoxy]ethoxy]anthraquinone (2.17 g, 0.005 m, C.I. Disperse Red 138 dry cake), 3-isopropenyl-α,α-dimethylbenzyl isocyanate (0.1.06 g, 0.005 m), toluene (30.0 mL) and dibutytin dilaurate (4 drops) was heated and stirred at 95-90° C. for about 2.5 h. Thin-layer chromatography (1:1 tetrahydrofuran:hexane) indicated a small amount of starting material. Additional 3-isopropenyl-α,α-dimethylbenzyl isocyanate (10-12 drops) was added and heating and stirring was continued at 90° C. for another hour. The reaction mixture was allowed to cool to 60° C. and gradually added to heptane (50 mL). The reaction mixture was allowed to cool to ambient temperature and red precipitate was collected by vacuum filtration. The precipitate was washed with heptane and dried in air (yield-3.10 g, 97.5% of the theoretical yield). FDMS supported the following structure:
[0055] An absorption maximum was observed at 517 nm (extinction coefficient=1.53×10 4 ) nm in the UV-visible absorption spectrum in DMF solvent.
Example 3
[0056] 1 -amino-4-hydroxy-2-[2′-[4′-(2′-hydroxyethoxy)phenoxy]ethoxy]anthraquinone (1.0 g, 0.0023 m, C.I. Disperse Red 138 dry cake), methacrylic anhydride (411 μL, 0.00276 m, 4-dimethylaminopyridine (28 mg, 0.00023 m), hydroquinone (10 mg) were added respectively to a 100 mL round-bottomed flask equipped with a magnetic stir bar that contained DMF (10.0 mL). Triethylamine (385 μL, 0.00276 m) was added dropwise to the stirring reaction solution. The reaction solution was stirred at ambient temperature for 24 h. Methanol (25 mL) was added to the reaction mixture. The reaction mixture was poured into 100 mL of water to precipitate the product, which was collected by vacuum filtration. The precipitate was washed with water and dried in air (yield-1.16 g, 100% of the theoretical yield). FDMS supported the following structure:
Examples 4-41
[0057] The colorants set forth in Table I were prepared according to the general method used to prepare the colorants of Examples 1 through 3. The colorants in Examples 4 through 41 had the following general structure as further defined in Table I.
TABLE I Olefin Substituted Red Anthraquinone Colorants Example R R 1 Y Q 4 —CH 2 CH 2 — —OH —O— —COC(CH 3 )═CH 2 5 —(CH 2 ) 3 — —OH —O— —COC(CH 3 )═CH 2 6 —(CH 2 ) 4 — —OH —O— —COCH═CH—CH 3 7 —(CH 2 ) 6 — —OH —O— —COC(CH 3 )═CH 2 8 —CH 2 CH 2 CH(CH 3 )— —OH —O— —CONHC(CH 3 ) 2 C 6 H 4 -3-C(CH 3 )═CH 2 9 —(CH 2 ) 8 — —OH —O— —CONHC(CH 3 ) 2 C(CH 3 )═CH 2 10 —CH 2 CH 2 OCH 2 CH 2 — —OH —O— —COCH═CH—C 6 H 5 11 —(CH 2 CH 2 O) 2 —CH 2 CH 2 O— —OH —O— 12 —CH 2 CH 2 SCH 2 CH 2 — —OH —O— —COCH═CH—CO 2 H 13 —CH 2 CH 2 N(SO 2 C 6 H 5 )CH 2 CH 2 — —OH —O— —COC(CH 3 )═CH 2 14 —CH 2 CH 2 N(SO 2 CH 3 )CH 2 CH 2 — —OH —O— —CONHC(CH 3 ) 2 C 6 H 4 -3-C(CH 3 )═CH 2 15 —CH 2 CH(OCOCH═CH 2 )CH 2 — —OH —O— —COCH═CH 2 16 —CH 2 CH 2 — —OH —NH— —COC(CH 3 )═CH 2 17 —(CH 2 ) 6 — —OH —N(CH 3 )— —CONHC(CH 3 ) 2 C 6 H 4 -3-C(CH 3 )═CH 2 18 —OH —O— —CONHC(CH 3 ) 2 C 6 H 4 -3-C(CH 3 )═CH 2 19 —OH —O— —COC 6 H 4 -4-CH═CH 2 20 —OH —O— 21 —CH 2 CH 2 N(COC 6 H 5 )CH 2 CH 2 — —OH —O— —CONHCH 2 CH 2 OCOC(CH 3 )═CH 2 22 —CH 2 CH 2 — —NHSO 2 CH 3 —O— —COC(CH 3 )═CH 2 23 —(CH 2 ) 6 — —NHSO 2 C 6 H 5 —O— —CONHC(CH 3 ) 2 C 6 H 4 -3-C(CH 3 )═CH 2 24 —NHC 4 H 9 -n —O— —CONHCOC(CH 3 )═CH 2 25 —CH 2 CH 2 OCH 2 CH 2 — —NHSO 2 C 6 H 4 -4-CH 3 —NH— —COCH═CH 2 26 —NHSO 2 C 6 H 11 —O— —COC(CH 3 )═CH 2 27 —CH 2 CH 2 N(C 6 H 5 )CH 2 CH 2 — —NHSO 2 CH 2 C 6 H 5 —O— —CONHC(CH 3 ) 2 C 6 H 4 -3-C(CH 3 )═CH 2 28 —CH 2 CH 2 CH(CH 3 )— —OH —O— —COC(CH 3 )═CH 2 29 —(CH 2 ) 8 — —OH —O— —COC(CH 3 )═CH 2 30 —CH 2 CH 2 OCH 2 CH 2 — —OH —O— —COC(CH 3 )═CH 2 31 —(CH 2 CH 2 O) 2 —CH 2 CH 2 O— —OH —O— —COC(CH 3 )═CH 2 32 —CH 2 CH 2 SCH 2 CH 2 — —OH —O— —COC(CH 3 )═CH 2 33 —(CH 2 ) 6 — —OH —N(CH 3 )— —COC(CH 3 )═CH 2 34 —OH —O— —COC(CH 3 )═CH 2 35 —OH —O— —COC(CH 3 )═CH 2 36 —OH —O— —COC(CH 3 )═CH 2 37 —CH 2 CH 2 N(COC 6 H 5 )CH 2 CH 2 — —OH —O— —COC(CH 3 )═CH 2 38 —(CH 2 ) 6 — —NHSO 2 C 6 H 5 —O— —COC(CH 3 )═CH 2 39 —NHC 4 H 9 -n —O— —COC(CH 3 )CH 2 40 —CH 2 CH 2 — —NHSO 2 C 6 H 4 -4-CH 3 —O— —COC(CH 3 )═CH 2 41 —CH 2 CH 2 — —NHSO 2 C 6 H 4 -4-CH 3 —O— —CONHC(CH 3 ) 2 C 6 H 4 -3-C(CH 3 )═CH 2
[0058] As stated above, the present invention also relates to a process for making concentrated solutions of red dyes in a suitable solvent. Suitable solvents include aromatics, ketones, acrylates, methacrylates, styrenes and the like. In the concentrates of the present invention, toluene, methylethyl ketone, acetone, hexanediol diacrylate, tri(propyleneglycol) diacrylate and mixtures thereof are preferred solvents. The concentration of dye in the solution can be from about 0.5 weight percent (wt %) to about 40 wt % and is preferably from about 10 wt % to about 30 wt %. The skilled artisan will understand that the foregoing ranges also include all fractions falling within these ranges, and that each of the lower ranges may be paired with the upper end ranges listed above.
[0059] In addition, the present invention relates to a coating composition containing photopolymerizable colorants of Formula I. Preferred coating substrates are thermoplastics, glass, wood, paper, metal and the like, particularly preferred thermoplastics are polyesters, acrylics and polycarbonate
[0060] The functionalized dyes or colorants which contain vinyl or substituted vinyl groups are polymerizable or copolymerizable, preferably by free radical mechanisms, said free radicals being generated by exposure to UV light by methods known in the art of preparing UV-cured resins. Polymerization can be facilitated by the addition of photoinitiators. The colored polymeric materials normally are prepared by dissolving the functionalized colorants containing copolymerizable groups in a polymerizable vinyl monomer with or without another solvent and then combining with an oligomeric or polymeric material which contains one or more vinyl or substituted vinyl groups.
[0061] The polymerizable vinyl compounds useful in the present invention contain at least one unsaturated group capable of undergoing polymerization upon exposure to UV radiation in the presence of a photoinitiator, i.e., the coating compositions are radiation-curable. Examples of such polymerizable vinyl compounds include acrylic acid, methacrylic acid and their anhydrides; crotonic acid; itaconic acid and its anhydride; cyanoacrylic acid and its esters; esters of acrylic and methacrylic acids such as allyl, methyl, ethyl, n-propyl, isopropyl, butyl, tetrahydrofurfuryl, cyclohexyl, isobornyl, n-hexyl, n-octyl, isooctyl, 2-ethylhexyl, lauryl, stearyl, and benzyl acrylate and methacrylate; and diacrylate and dimethacrylate esters of ethylene and propylene glycols, 1,3-butylene glycol, 1,4-butanediol, diethylene and dipropylene glycols, triethylene and tripropylene glycols, 1,6-hexanediol, neopentyl glycol, polyethylene glycol, and polypropylene glycol, ethoxylated bisphenol A, ethoxylated and propoxylated neopentyl glycol; triacrylate and trimethacrylate esters of tris-(2-hydroxyethyl)isocyanurate, trimethylolpropane, ethoxylated and propoxylated trimethylolpropane, pentaerythritol, glycerol, ethoxylated and propoxylated glycerol; tetraacrylate and tetramethacrylate esters of pentaerythritol and ethoxylated and propoxylated pentaerythritol; acrylonitrile; vinyl acetate; vinyl toluene; styrene; N-vinyl pyrrolidinone; alpha-methylstyrene; maleate/fumarate esters; maleic/fumaric acid; crotonate esters, and crotonic acid.
[0062] The polymerizable vinyl compounds useful in the present invention include polymers which contain unsaturated groups capable of undergoing polymerization upon exposure to UV radiation in the presence of a photoinitiator. The preparation and application of these polymerizable vinyl compounds are well known to those skilled in the art as described, for example, in Chemistry and Technology of UV and EB Formulation for Coatings, Inks, and Paints , Volume II: Prepolymers and Reactive Diluents, G. Webster, editor, John Wiley and Sons, London, 1997. Examples of such polymeric, polymerizable vinyl compounds include acrylated and methacrylated polyesters, acrylated and methacrylated polyethers, acrylated and methacrylated epoxy polymers , acrylated or methacrylated urethanes, acrylated or methacrylated polyacrylates (polymethacrylates), and unsaturated polyesters. The acrylated or methacrylated polymers and oligomers typically are combined with monomers which contain one or more acrylate or methacrylate groups, e.g., monomeric acrylate and methacrylate esters, and serve as reactive diluents. The unsaturated polyesters, which are prepared by standard polycondensation techniques known in the art, are most often combined with either styrene or other monomers, which contain one or more acrylate or methacrylate groups and serve as reactive diluents. Another embodiment for the utilization of unsaturated polyesters that is known to the art involves the combination of the unsaturated polyester with monomers that contain two or more vinyl ether groups or two or more vinyl ester groups (WO 96/01283, WO 97/48744, and EP 0 322 808).
[0063] The coating compositions of the present invention optionally may contain one or more added organic solvents if desired to facilitate application and coating of the compositions onto the surface of substrates. Typical examples of suitable solvents include, but are not limited to ketones, alcohols, esters, chlorinated hydrocarbons, glycol ethers, glycol esters, and mixtures thereof. Specific examples include, but are not limited to acetone, 2-butanone, 2-pentanone, ethyl acetate, propyl acetate, isopropyl acetate, butyl acetate, isobutyl acetate, ethylene glycol diacetate, ethyl 3-ethoxy propionate, methyl alcohol, ethyl alcohol, propyl alcohol, isopropyl alcohol, butyl alcohol, ethylene glycol, propylene glycol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monopropyl ether, ethylene glycol monobutyl glycol, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, diethylene glycol monobutyl ether, propylene glycol monomethyl ether, diethylene glycol monobutyl ether acetate, diethylene glycol monoethyl ether acetate, ethylene glycol monobutyl ether acetate, propylene glycol monomethyl ether acetate, methylene chloride, chloroform, toluene, xylene and mixtures thereof. Preferred mixtures of solvents may include esters, ketones and aromatic solvents such as toluene, xylene, acetone, 2-pentanone, ethyl acetate and the like. The amount of added or extraneous solvent which may be present in our novel coating compositions may be in the range of about 1 to 40 weight percent, more typically about 1 to 25 weight percent, based on the total weight of the coating composition.
[0064] Certain polymerizable vinyl monomers may serve as both reactant and solvent. These contain at least one unsaturated group capable of undergoing polymerization upon exposure to UV radiation in the presence of a photoinitiator. Specific examples include, but are not limited to: methacrylic acid, acrylic acid, ethyl acrylate and methacrylate, methyl acrylate and methacrylate, hydroxyethyl acrylate and methacrylate, diethylene glycol diacrylate, trimethylolpropane triacrylate, 1,6 hexanediol di(meth)acrylate, neopentyl glycol diacrylate and methacrylate, vinyl ethers, divinyl ethers such as diethyleneglycol divinyl ether, 1,6-hexanediol divinyl ether, cyclohexanedimethanol divinyl ether, 1,4-butanediol divinyl ether, triethyleneglycol divinyl ether, trimethylolpropane divinyl ether, and neopentyl glycol divinyl ether, vinyl esters, divinyl esters such as divinyl adipate, divinyl succinate, divinyl glutarate, divinyl 1,4-cyclohexanedicarboxylate, divinyl 1,3-cyclohexanedicarboxylate, divinyl isophthalate, and divinyl terephthalate, N-vinyl pyrrolidone, and mixtures thereof.
[0065] In addition, the compositions of the present invention may be dispersed in water rather than dissolved in a solvent to facilitate application and coating of the substrate surface. In the water-dispersed compositions of the present invention a co-solvent is optionally used. Typical examples of suitable cosolvents include but are not limited to acetone, 2-butanone, methanol, ethanol, isopropyl alcohol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monopropyl ether, and ethylene glycol monobutyl ether, ethylene glycol, and propylene glycol. Typical examples of water-soluble ethylenically unsaturated solvents include but are not limited to: methacrylic acid, acrylic acid, N-vinyl pyrrolidone, 2-ethoxyethyl acrylate and methacrylate, polyethylene glycol dimethacrylate, polypropylene glycol monoacrylate and monomethacrylate, and mixtures thereof. The amount of suitable aqueous organic solvent (i.e., organic solvent and water) in the dispersed coating compositions of the present invention is about 10 to about 90 weight percent, preferably about 75 to about 90 weight percent of the total coating composition.
[0066] The coating compositions of the present invention contain one or more of the ethylenically unsaturated dye compounds described herein. The concentration of the ethylenically unsaturated dye compound or compounds may be from about 0.005 to about 40.0 weight percent but is preferably from about 0.5 to about 30, weight percent based on the weight of the polymerizable vinyl compound(s) present in the coating composition, i.e., component (i) of the coating compositions.
[0067] The coating compositions of the present invention normally contain a photoinitiator. The amount of photoinitiator typically is about 1 to 15 weight percent, preferably about 3 to about 5 weight percent, based on the weight of the polymerizable vinyl compound(s) present in the coating composition. Typical photoinitiators include benzoin and benzoin ethers such as marketed under the tradenames ESACURE BO, EB1, EB3, and EB4 from Fratelli Lamberti; VICURE 10 and 30 from Stauffer; benzil ketals such as 2,2-dimethoxy-1,2-diphenylethan-1-one (IRGACURE 651), 2-hydroxy-2-methyl-1-phenylpropan-1-one (IRGACURE 1173), 2-methyl-2-morpholino-1-(p-methylthiophenyl)propan-1-one (IRGACURE 907), alpha-hydroxyalkyl-phenones such as (1-hydroxycyclohexyl)(phenyl)methanone (IRGACURE 184), 2-benzyl-2-(dimethylamino)-1-(4-morpholinophenyl)butan-1-one (IRGACURE 369), 2-hydroxy-2-methyl-I-phenylpropan-1-one IRGACURE 1173) from Ciba Geigy, Uvatone 8302 by Upjohn; alpha, alpha-dialkoxyacetophenone derivatives such as DEAP and UVATONE 8301 from Upjohn; DAROCUR 116, 1173, and 2959 by Merck; and mixtures of benzophenone and tertiary amines In pigmented coating compositions, the rate of cure can be improved by the addition of a variety of phosphine oxide photoinitiaters such as bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide (IRGANOX 819), IRGACURE 819, 1700, and 1700 and phosphine oxide mixtures such as a 50/50 by weight mixtures of IRGACURE 1173 and 2,4,6-trimethylbenzoyldiphenylphosphine oxide (DAROCUR 4265) from Ciba. Further details regarding such photoinitiators and curing procedures may be found in the published literature such as U.S. Pat. No. 5,109,097, incorporated herein by reference. Depending upon the thickness of the coating (film), product formulation, photoinitiator type, radiation flux, and source of radiation, exposure times to ultraviolet radiation of about 0.5 second to about 30 minutes (50-5000 mJ/square cm) typically are required for curing. Curing also can occur from solar radiation, i.e., sunshine.
[0068] The coating compositions of the present invention may contain one or more additional components typically present in coating compositions. Examples of such additional components include leveling, rheology, and flow control agents such as silicones, fluorocarbons or cellulosics; flatting agents; pigment wetting and dispersing agents; surfactants; ultraviolet (UV) absorbers; UV light stabilizers; tinting pigments; defoaming and antifoaming agents; anti-settling, anti-sag and bodying agents; anti-skinning agents; anti-flooding and anti-floating agents; fungicides and mildewcides; corrosion inhibitors; thickening agents; and/or coalescing agents. The coating compositions of the present invention also may contain non-reactive modifying resins. Typical non-reactive modifying resins include homopolymers and copolymers of acrylic and methacrylic acid; homopolymers and copolymers of alkyl esters of acrylic and methacrylic acid such as methyl, ethyl, n-propyl, isopropyl, butyl, tetrahydrofurfuryl, cyclohexyl, isobornyl, n-hexyl, n-octyl, isooctyl, 2-ethylhexyl, lauryl, stearyl, and benzyl acrylate and methacrylate; acrylated and methacrylated urethane, epoxy, and polyester resins, silicone acrylates, cellulose esters such as cellulose acetate butyrates, cellulose acetate, propionates, nitrocellulose, cellulose ethers such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, and hydroxypropyl methyl cellulose.
[0069] Typical plasticizers include alkyl esters of phthalic acid such as dimethyl phthalate, diethyl phthalate, dipropyl phthalate, dibutyl phthalate, and dioctyl phthalate; citrate esters such as triethyl citrate and tributyl citrate; triacetin and tripropionin; and glycerol monoesters such as Eastman 18-04, Eastman 18-07, Eastman 18-92 and Eastman 18-99 from Eastman Chemical Company. Specific examples of additional additives can be found in Raw Materials Index , published by the National Paint & Coatings Association, 1500 Rhode Island Avenue, N.W., Washington, D.C. 20005.
[0070] As disclosed herein, the coating compositions of the present invention may be prepared as a result of a UV cure process but the method by which cure occurs is not a limiting aspect of the invention. One skilled in the art appreciates other free radical initiators such as peroxides and related compounds that decompose to give species that can initiate polymerization of unsaturated monomers such as methyl acrylate, hydroxyethyl methacrylate and the like.
[0071] The polymeric coatings of the present invention typically have a solvent resistance of at least 100 MEK double rubs using ASTM Procedure D-3732; preferably a solvent resistance of at least about 200 double rubs. Such coatings also typically have a pencil hardness of greater than or equal to F using ASTM Procedure D-3363; preferably a pencil hardness of greater than or equal to H. The coating compositions can be applied to substrates with conventional coating equipment. The coated substrates are then exposed to radiation such as ultraviolet light in air or in nitrogen which gives a cured finish. Mercury vapor or Xenon lamps are applicable for the curing process. The coatings of the present invention can also be cured by electron beam.
[0072] The radiation-curable coating compositions of this invention are suitable as adhesives and coatings for such substrates as metals such as aluminum and steel, plastics, glass, wood, paper, and leather. On wood substrates the coating compositions may provide both overall transparent color and grain definition. Various aesthetically-appealing effects can be achieved thereby. Due to reduced grain raising and higher film thicknesses, the number of necessary sanding steps in producing a finished wood coating may be reduced when using the colored coating compositions of the invention rather than conventional stains. Coating compositions within the scope of our invention may be applied to automotive base coats where they can provide various aesthetically-appealing effects in combination with the base coats and color differences dependent on viewing angle (lower angles create longer path lengths and thus higher observed color intensities). This may provide similar styling effects as currently are achieved with metal flake orientation in base coats. Coating compositions within the scope of our invention may be applied to window films that may be suitable for automotive and architectural applications. Coating compositions within the scope of our invention may be applied to glass such as a fiber optic cable.
[0073] Various additional pigments, plasticizers, and stabilizers may be incorporated to obtain certain desired characteristics in the finished products. These are included in the scope of the invention.
[heading-0074] Coating Examples
[0075] The coatings and coating compositions provided by the present invention and the preparation thereof are further illustrated by the following examples.
Example 42
[0076] This Example is a “control” experiment. A photopolymerizable composition consisting of 8.09 g Jägalux UV1500 polyester acrylate, 3.96 g of bisphenol A epoxy acrylate, 3.58 g dipropyleneglycol diacrylate (DPGDA), 2.83 g trimethylolpropane triacrylate (TMPTA), and 1.06 g of Darocure 1173 photoinitiator was prepared by mixing until the components were completely dispersed. The resulting coating composition was drawn down with a wire wound rod to provide a 4-10 micron thick wet coating on a 4″×4″ glass plate, 4″×4″ Spectar® (Eastman Chemical Company) plaque, 3″×6″ aluminum plate and a 3″×6″ rolled steel plate. Each panel was passed through a UV cure machine at a speed of 7.3 meters per minute (24 feet/minute) using a lamp with an intensity of 118.1 watts per cm (300 watts per inch). Konig Pendulum Hardness measurements (ASTM D4366 DIN 1522) were conducted on the each coated substrate and indicated a hard coating was obtained (Table II). Chemical resistance was tested with MEK double rubs. The coating withstood more than 300 MEK double rubs.
Example 43
[0077] A colored, photopolymerizable composition was prepared by thoroughly mixing 0.2 g the red dye of Example 1 with a coating composition consisting of 8.89 g Jägalux UV1500 polyester acrylate, 4.25 g of bisphenol A epoxy acrylate, 3.62 g dipropyleneglycol diacrylate (DPGDA), 2.83 g trimethylolpropane triacrylate (TMPTA), and 1.01 g of Darocure 1173 photoinitiator until the components were completely dispersed. The resulting coating composition containing approximately 1% of the red dye was drawn down with a wire wound rod to provide a 4-10 micron thick wet coating on a 4″×4″ glass plate, 4″×4″ Spectar® plaque, 3″×6″ aluminum plate and a 3″×6″ rolled steel plate. Each panel was passed through a UV cure machine at a speed of 7.3 meters per minute (24 feet/minute) using a lamp with an intensity of 118.1 watts per cm (300 watts per inch). Konig Pendulum Hardness measurements (ASTM D4366 DIN 1522) were conducted on the each coated substrate and indicated no significant loss of hardness due to incorporation of the dye (Table II). Chemical resistance was tested with MEK double rubs. Both the control (Examples 46-49), which contained no polymerizable dye, and the coatings, which contained polymerizable dyes (Examples 50-53), withstood more than 300 MEK double rubs. No dye color was observed on the white cheesecloth of the MEK rub test, which is an indication that the dyes cannot be extracted from the coatings with solvents and demonstrates complete incorporation of the dye into the polymer matrix of the cured film.
Example 44
[0078] A colored, photopolymerizable composition was prepared by thoroughly mixing 0.2 g of the red dye of Example 41 with a coating composition consisting of 7.98 g Jägalux UV1500 polyester acrylate, 4.08 g of bisphenol A epoxy acrylate, 3.69 g dipropyleneglycol diacrylate (DPGDA), 2.84 g trimethylolpropane triacrylate (TMPTA), and 1.01 g of Darocure 1173 photoinitiator until the components were completely dispersed. The resulting coating composition containing approximately 1% of the red dye was drawn down with a wire wound rod to provide a 4-10 micron thick wet coating on a 4″×4″ glass plate, 4″×4″ Spectar® plaque, 3″×6″ aluminum plate and a 3″×6″ rolled steel plate. Each panel was passed through a UV cure machine at a speed of 7.3 meters per minute (24 feet/minute) using a lamp with an intensity of 118.1 watts per cm (300 watts per inch). Konig Pendulum Hardness measurements (ASTM D4366 DIN 1522) were conducted on the each coated substrate and indicated no significant loss of hardness due to incorporation of the dye (Table II). Chemical resistance was tested with MEK double rubs. Both the control (Examples 46-49), which contained no polymerizable dye, and the coatings, which contained polymerizable dyes (Examples 54-57), withstood more than 300 MEK double rubs. No dye color was observed on the white cheesecloth of the MEK rub test, which is an indication that the dyes cannot be extracted from the coatings with solvents and demonstrates complete incorporation of the dye into the polymer matrix of the cured film.
Example 45
[0079] A colored, photopolymerizable composition was prepared by thoroughly mixing 0.2 g of the red dye of Example 3 with a coating composition consisting of 7.98 g Jägalux UV1500 polyester acrylate, 4.08 g of bisphenol A epoxy acrylate, 3.69 g dipropyleneglycol diacrylate (DPGDA), 2.84 g trimethylolpropane triacrylate (TMPTA), and 1.01 g of Darocure 1173 photoinitiator until the components were completely dispersed. The resulting coating composition containing approximately 1% of the red dye was drawn down with a wire wound rod to provide a 4-10 micron thick wet coating on a 4″×4″ glass plate, 4″×4″ Spectar® plaque, 3″×6″ aluminum plate and a 3″×6″ rolled steel plate. Each panel was passed through a UV cure machine at a speed of 7.3 meters per minute (24 feet/minute) using a lamp with an intensity of 118.1 watts per cm (300 watts per inch). Konig Pendulum Hardness measurements (ASTM D4366 DIN 1522) were conducted on the each coated substrate and indicated no significant loss of hardness due to incorporation of the dye (Table II). Chemical resistance was tested with MEK double rubs. Both the control (Examples 46-49), which contained no polymerizable dye, and the coatings, which contained polymerizable dyes (Examples 59-61), withstood more than 300 MEK double rubs. No dye color was observed on the white cheesecloth of the MEK rub test, which is an indication that the dyes cannot be extracted from the coatings with solvents and demonstrates complete incorporation of the dye into the polymer matrix of the cured film.
Examples 46-61
[0080] Examples 46 through 61, which are set forth in Table II, reflect Konig Pendulum Hardness measurements for various coated substrates using the coatings in Examples 42 through 45.
TABLE II Konig Pendulum Hardness Measurement Data for coated Substrates Example # Substrate Coating Trial 1 Trial 2 46 aluminum Example 42 231 231 47 glass Example 42 127 137 48 rolled steel Example 42 218 206 49 Spectar ® Example 42 243 245 50 aluminum Example 43 207 190 51 glass Example 43 110 108 52 rolled steel Example 43 191 193 53 Spectar ® Example 43 227 227 54 aluminum Example 44 138 158 55 glass Example 44 112 119 56 rolled steel Example 44 175 161 57 Spectar ® Example 44 224 227 58 aluminum Example 45 179 179 59 glass Example 45 113 112 60 rolled steel Example 45 172 173 61 Spectar ® Example 45 221 224
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | This invention pertains to certain novel red anthraquinone colorant compounds containing one or more ethylenically-unsaturated (e.g., vinyl), photopolymerizable radicals that may be copolymerized (or cured) with ethylenically-unsaturated monomers to produce colored compositions such as colored acrylic polymers. Suitable compositions having the present colorants copolymerized therein include, e.g., polymers produced from acrylate and methacrylate esters, colored polystyrenes, and similar colored polymeric materials derived from other ethylenically-unsaturated monomers. The novel colorants possess good fastness (stability) to ultraviolet (UV) light, good solubility in vinyl monomers and good color strength. The present invention also pertains to processes for preparing the photopolymerizable colorant compounds. The ethylenically unsaturated colorant compounds may be suitable for use in coatings that are applied to wood, glass, paper, metal, thermoplastics and the like. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority pursuant to 35 USC §119(e)(1) from the provisional patent applications filed pursuant to 35 USC §111(b): as Ser. No. 60/037,876 on Feb. 10, 1997, and as Ser. No. 60/045,368 on May 2, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the present invention relates generally to improvements in portable environmental barriers, and more particularly to a portable screen that can be easily carried by a user in a compact configuration. Portable screen barriers are particularly useful in outdoor environments to provide protection from blowing dirt, sand, and other debris. When used as a wind barrier, these devices are especially useful in beach environments, where wind blown sand and other debris may be a nuisance. Alternative uses for the portable environmental barrier of the present invention include a child or pet restraint enclosure, a privacy barrier, and a temporary equipment and personal effect storage site.
2. Brief Discussion of the Prior Art
The use of portable screen apparatusses in various environments is known in the prior art. In an outdoor environment, the use of environmental screens is desirable to prevent wind-blown dirt, sand, and other debris from contacting the user thereof or otherwise being deposited on or near the user. Additionally, environmental screens may desirably provide a degree of privacy to a user or group of users. Prior art environmental screens may be large fixed screens typically in the form of walls or fences. While such fixed screens are effective in providing protection against the wind and blowing objects, they are of course expensive, stationary structures which are impossible to transport. As a result, for those who find themselves outdoors on windy days either move to the shelter of a fixed wind fence or else suffer the discomfort and inconvenience of wind and blowing dirt and sand.
BRIEF SUMMARY OF THE INVENTION
The present invention specifically addresses the above mentioned deficiencies of the prior art wind screens. More particularly, and in illustrated embodiments, the present invention is a portable environmental barrier for outdoor use which can be stowed and user-carried within a "duffle-bag" or similar flexible bag appliance. The environmental barrier of the present invention may easily be carried by a user when packaged in a non-functional configuration within the bag, and deployed in a functional configuration to adequately protect the user from blowing grass, sand, and other debris. Additional uses for the present invention include a child or pet restraint enclosure and a privacy screen. Still another use for the present invention is as an enclosure for equipment and personal effects for members of a team participation event. A banner or other indicia may be associated with separate enclosures of the present invention to identify particular teams, groups, etc. Advantageously, the portable barrier of the present invention can be quickly erected for use in a wide variety of outdoor settings, e.g., beaches, sporting events, picnic areas, camping sites, etc. The portable environmental barrier includes a plurality of rectangular barrier panel members, which preferably may be formed from a single sheet of light weight fabric or other flexible material. The barrier panel members are supported in a generally vertical plane by support members which are secured at intervals along the length of the environmental barrier. The support members may be multi-part poles which may be deployed from a collapsed storage orientation. Still another aspect of the present invention provides that the barrier panel members, when transported or stored, may be folded or otherwise accumulated for user transport within a bag. The bag device may be separable from the environmental barrier device to allow individual use once the environmental barrier is erected. The bag device may include a plurality of pockets or enclosures for user storage. Still another aspect of the present invention provides accessory enclosure panels which may be attached to the erected environmental barrier to form a substantially enclosed region for additional privacy, protection from the sun, or storage of personal effects and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view of a deployed environmental barrier according to the present invention;
FIG. 2 is a side elevational view of an environmental barrier according to the present invention shown in an alternative deployed configuration;
FIG. 3 is a partial top plan view of the environmental barrier of FIGS. 1 and 2;
FIG. 4 is an enlarged partial perspective view of the environmental barrier of FIGS. 1 and 2;
FIG. 5 is a side elevation view of the pole members of the present invention;
FIG. 6 is a cross sectional view of the environmental barrier of FIG. 2, taken along lines 6--6;
FIG. 7 is a partial top view of the environmental barrier of FIG. 1;
FIG. 8 is a partial side elevational view of the environmental barrier of FIG. 1; and
FIG. 9 is a cross sectional view of the environmental barrier of FIG. 8, taken along lines 9--9
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in detail, the numeral 10 designates the environmental barrier device as a whole. The environmental barrier device 10 is illustrated in deployed orientations in FIGS. 1 and 2. As best illustrated in FIG. 1, the environmental barrier 10 includes a plurality of flexible barrier panel members 12 which are supported in generally vertical planes by pole members 14, shown here as collapsible poles 14. Device 10 further includes a bag device 16 or similar user-carried appliance which is adapted to contain the plurality of barrier panel members 12 and pole members 14. Bag device 16, as illustrated in FIG. 2, may also be supported by poles 14 in an upright manner. Alternatively bag device 16 may be detached from the environmental barrier structure 10 and separably utilized. Environmental barrier 10 may be erected upon sand other soil types in a variety of functional configurations. For instance, the environmental barrier 10 shown in FIG. 1 has been erected to enclose an area within the environmental barrier 10. Such a configuration may be desired to provide a degree of privacy to the user or provide a safety enclosure for children or pets. The deployed configuration of the barrier 10 of FIG. 1 may also be used as an equipment deposit site or team gathering location for outdoor team events. Alternatively with reference to FIG. 2, the environmental barrier 10 may be linearly erected, i.e. used as a wind fence structure.
Referring to FIGS. 1 and 2, environmental barrier 10 is illustrated in deployed functional orientations. Individual barrier panel members 12 may be manufactured from flexible material or fabric alternatives. In one embodiment, a single length of rip-stop nylon may be used as the barrier panel members 12. Barrier panel members 12 are supported at either end by poles 14 which interact with support structures 18. In the illustrated embodiments, support structures 18 are sleeves being orthogonally aligned relative to the longitudinal extent of each barrier panel member 12. Referring to FIGS. 2 and 6, individual support structures 18' may alternatively be formed by a pinch and sew procedure 17 to form a light fitting sleeve 18' for the poles 14 to slide through and support the barrier panel members 12. Furthermore, it is appreciated that support structures 18 may be formed in a variety of manners so that the barrier panel members 12 can be supported by poles 14. For instance, the poles 14 may be received through elongated sleeves 18' that span the height of the barrier panel members 12. As still further examples, support structure 18 may include loops through which poles 14 may be threaded, hook and loop fastener loops or tabs, and other securing structure for temporarily maintaining contact between a pole 14 and a barrier panel member 12. As a result, a variety of pole 14/barrier panel member 12 support interface techniques are appreciated by those skilled in the art.
Still referring to FIGS. 1 and 2, device 10 of the present invention includes a detachable bag 16. Bag 16 includes a body 20 having an interior region 22 and a handle structure 24 adapted for grasp by a user. The interior region 22 of the bag 16 is preferably sized to receive the undeployed plurality of barrier panel members 12 and support poles 14. Bag 16 is temporarily attached to the barrier panel member 12 by securement structure including a flexible securement panel 27 and an attachment structure 26, which may be a zipper, buttons, a hook and loop type fastening system, or other known fastening structure. The bag 16 may be detached from the barrier structure 12 and separably utilized for carrying or storage purposes. Alternatively, as illustrated in FIG. 2, the bag 16 may remain secured to the barrier panel members 12 and be supported in an upright manner by a pole support 14 and support structure 18. Still additionally the bag 16 may include pockets or insulated regions 28 for storage of food, personal effects, or accessories which are readily accessible to the user within the barrier 10 enclosure. The bag device 16 is illustrated as a soft-sided, "duffle" style bag, though alternatively a variety of bag styles, configurations, and shapes may be practicably adapted for use with the present invention.
Referring now to FIGS. 2, 4, and 6, the device 10 further includes a plurality of fastening structure 30 for temporarily securing the barrier panel members 12 to the poles 14. The fastening structure 30, which facilitates maintaining the barrier panel members 12 upon the pole 14 during use, may be a hook and loop fastener 31 affixed to the pole 14 and an inner surface of the support structure 18. Alternatively, the fastening structure 30 may include a small hook fastened to the pole 14 and engaging the barrier panel member 12 near its lower edge (not shown). Other types of fastening structure 30 may be appreciated by those skilled in the art.
Referring now to FIG. 5, a pair of poles 14 are shown, illustrating the functional and non-functional configurations for the poles 14. Poles 14 are collapsible two-part poles 14 as well known in the art. Each pole member 14 has a sharpened end 46 for soil penetration and a blunt end 48 for applying a downward penetrating force. As shown in FIGS. 2, 5, and 6, each pole member 14 may include a depth indicia 47 for indicating to the assembler the desired depth to which the pole 14 is inserted into the soil. Depth indicia 47 may be a line marking on the pole 14, an O-ring secured to the pole, or any other visible marking(s). In an illustrated embodiment, depth indicia 47 is spaced approximately 8 inches away from a sharpened end 46 of a pole 14. Other muftiple-part poles 14 may be practicable. Furthermore, a variety of pole configurations and materials of construction may be selected.
Bag 16 may include additional pockets for accessory storage. It is readily appreciated that bag 16 can be user supported through handle structure 24. The bag 16 includes a sealing structure 38 for enclosing the barriers 12 within the bag 16. The sealing structure 38 may be a zipper, buttons, a hook and loop structure, or other known sealing devices.
Referring again to FIGS. 1, 7, 8, and 9, another aspect of the present invention includes an accessory enclosure structure 50 providing a substantially enclosed region 52 for additional user privacy or protection. As illustrated in FIGS. 7 and 8, accessory enclosure structure 50 may include a top, generally triangularly-formed panel 54 and a side panel 56 having an opening 58 for the user, both panels 54, 56 being supported by a support pole 14. In the embodiment illustrated in FIGS. 1, 7, and 8, the accessory enclosure panels 54, 56 are temporarily secured at a comer of the erected barrier panel members 12. The accessory enclosure panels 54, 56 may be secured to the barrier panel members 12 in a variety of known manners, e.g., zippers, buttons, hook and loop fasteners 60, etc. Alterative attachable accessory enclosure structures 50 are readily appreciated by those skilled in the art. With particular reference to FIGS. 7, 8, and 9, the top panel 54 is secured to the barrier panel members 12 with a hook and loop-type fastener 62 which is positioned between an inner surface 64 of the barrier panel members 12 and an outer surface 66 of top panel 54. Positioning the fastener 62 in this manner reduces the "billowing" effect of wind passing underneath the top panel 54 and into the enclosed region 52.
In operation, the user may transport the device 10 in the non-functional orientation within the bag 16 to an outdoor location. When desired the user releases the environmental barrier device 10 by opening the sealing structure 38 and un-rolling the plurality of barrier panels 12. The poles 14 are then extended or otherwise manipulated to length and individually inserted into the support structures 18 of the barrier panel members 12. The securement devices 30 are then fastened to maintain the barrier panel members 12 to the poles 14. The device 10 may then be erected in a variety of configurations, i.e., as an enclosure of FIG. 1, a fence illustrated in FIG. 2, etc., by inserting the sharpened portion 46 of the poles 14 into the soil a desired locations to a proper depth indicated by the pole depth indicia 47. The accessory enclosure structure 50 may next be erected by attaching the enclosure structure 50 at a corner of the plurality barrier panels 12 with fasteners 60, 62. User access to the interior region 52 of the enclosure structure may be made through the opening 58 in the side panel 56. If desired, the user may support the bag 16 with one or more poles 14 in a generally upright manner to form an additional wind barrier section and facilitate user access to the pockets within the bag 16. Alternatively, once the barrier panel members 12 are erected, the user may detach the bag 16 from the barrier panel members 12 and separably use the bag 16 for storage or transport or other use. Upon departure from the outdoor location the user may collapse the device 10, remove the poles 14 from the sleeves 18, fold or otherwise accumulate the plurality of barrier panel members 12, place the collapsed poles 14 in the inner pockets 34 of the bag 16, and enclose the barrier panel members 12 within the bag 16 with sealing structure 38.
It is understood that the exemplary portable environmental barrier 10 described herein and shown in the drawings represents only a presently preferred embodiment of the invention. Indeed, various modifications and additions may be made to such embodiment without departing from the spirit and scope of the invention. Thus, these and other modifications and additions may be obvious to those skilled in the art and may be implemented to adapt the present invention for use in a variety of different applications. | A portable barrier apparatus is disclosed in this specification defining a multi-sectioned barrier for protection against wind and sand in various outdoor environments. Additionally the barrier may assembled and used as a child or pet restraint enclosure, a privacy barrier, or a temporary personal effect storage site. The apparatus includes a connected plurality of flexible barrier panel members which may be supported in an upright manner with a plurality of pole members. The apparatus further includes a bag or similar device for transporting the barrier in an undeployed configuration. The invention provides that the bag can be independently utilized away from the barrier. The invention further provides an accessory enclosure structure which is attachable to the barrier. | 8 |
FIELD OF THE INVENTION
This invention generally relates to novel polymers of 1-butene. More particularly, this invention relates to elastomeric polybutylene-1 polymers.
BACKGROUND OF THE INVENTION
Thermoplastic, predominantly isotactic homo- and copolymers of 1-butene, commonly referred to as poly-1-butene or polybutylene (conventional polybutene-1) are known in the art. Elastomeric polymers including elastomeric polybutylene-1 are also known in the art. In certain applications, there has been an effort to replace conventional polybutylene-1 with elastomeric polybutylene-1. These applications include film sheets and packaging film where the elastic nature of the elastomeric polybutylene-1 is preferred.
Packaging films are required to have certain characteristics which are desirable for the particular application. For example, films which are used for wrapping food such as vegetables, meat or fish, are minimally required to have a good puncture resistance and a good elastic recovery, sometimes also referred to as memory. A good puncture resistance is particularly important when packaging meat with bones because of the greater likelihood of the bones puncturing the film. Good recovery properties are particularly important in packaging food. Usually, the food is sold in service or convenience stores, or in grocery stores where many customers touch the packages. These touchings deform the film, and without the ability to sufficiently recover, the packaged food looks unfresh and often cannot be sold anymore.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an elastomeric polybutylene-1 having significantly improved properties.
It is a further object of the invention to provide an elastomeric polybutylene-1 having a significant amount of syndiotacticity.
Accordingly, it is now provided an elastomeric polybutylene-1 having and exhibiting syndiotacticity of greater than ten (10) percent.
The inventive elastomeric polybutylene-1 can be blended with compatible materials such as polypropylene and its copolymers, ethylene-propylene block copolymers, butyl rubbers, and polyisobutylene into a composition having soft and improved elastic properties. Such compositions are particularly suitable in films, hot melt adhesives, textile and fiber applications.
The novel elastomeric polybutylene-1 can also be blended with incompatible materials such as ethylenically unsaturated esters (EVA, EMA, EMAA, EEA), polyester, nylon, polystyrene, styrene block copolymers (SEBS, SIS, SBS) and polyethylenes. Such blends are particularly useful in easy-open packaging and foam applications and in PVC replacement. When oriented, films made of such blends are used as soft and elastic shrink films.
The novel elastomeric polybutylene-1 can also be blended with both incompatible and compatible materials wherein such materials are as previously disclosed.
The inventive elastomeric polybutylene-1 composition also has utility in automotive and hot melt adhesive applications, and in the manufacturing of disposable products.
DETAILED DESCRIPTION OF THE INVENTION
Polybutylene polymers are well known in the art. These polymers can be homopolymers or copolymers. The homopolymers of polybutylene can be further classified into isotactic, atactic, or syndiotactic. Conventional polybutylene is predominantly isotactic and has a high degree of crystallinity. Prominently useful properties of conventional isotactic polybutylene include toughness, resistance to creep, and resistance to environmental stress cracking. These properties enable conventional isotactic polybutylene to be useful in applications such as pipe or tubing, films, and polymer modifications.
Another type of polybutylene known in the art is elastomeric polybutylene. Elastomeric polybutylene, like conventional polybutylene, is highly stereoregular. However, unlike conventional polybutylene, it has a lesser degree of crystallinity, and exhibits physical properties which more closely parallel those of thermoplastic elastomers such as commercial block copolymers based on styrene and diolefins or complex blends of polypropylene with elastomeric copolymers of ethylene and propylene.
A prominent feature of elastomeric polybutylene is its substantially suppressed level of crystallinity compared to conventional polybutylenes. A companion feature of the elastomeric polybutylene, one which makes it unique among the large number of polyolefins produced with stereoselective catalyst, is the fact that this suppression of crystallinity is achieved without a corresponding large increase in amount of easily extractable polymer (soluble in refluxing diethyl ether). This unusually low ether solubles content makes possible film use for medical and food packages that cannot tolerate substantial leaching of the plastic into the solutions or food.
Another distinguishing feature of the novel elastomeric polybutylene is its 13 C NMR spectrum. The 13 C NMR method provides detailed information about the configuration and conformation of short sections of polymer chains. A comparison of the 13 C NMR spectra of conventional polybutylene with that of the novel elastomeric polybutylene indicates a significant difference between the polymers, even though they both have a very high degree of steric order. The difference shows up in the elastomeric polybutylene as a higher proportion of polymer which comprises of short sequences of frequent tactic inversion alternating with longer isotactic sequences. This indicates a molecular structure of relatively short average isotactic sequences, which contrasts strikingly with the structure of long average isotactic sequences of conventional polybutylene. The elastomeric polybutylene consists mainly of isotactic blocks, interrupted by inversions of only one or a few monomer units largely in alternating (syndiotactic) stereochemical configurations.
Elastomeric polybutylene having a wide range of molecular weights may be produced. Number average molecular weights (Mn) may be from 20,000 to 300,000 and weight average molecular weights (Mw) from 150,000 to 2,200,000. A characteristic of the novel elastomeric polybutylene of this invention is a narrow molecular weight distribution, as indicated by the ratio of Mw/Mn (Q-value) which is typically in the order of 70 to 75% wt or less than the Q-value of conventional polybutylene.
Both conventional and elastomeric isotactic polybutylene are unique compared to other commercial polyolefins in that they are capable of existing in several crystalline modifications which can be isolated in almost pure form. Conventional isotactic polybutylene typically first solidifies from the melt in the crystal form known as Type II. Type II is unstable with respect to Type I and converts to Type I at a rate depending on a variety of factors, such as molecular weight, tacticity, temperature, pressure, and mechanical shock. Properties of the several crystal forms of conventional isotactic polybutylene are well known. The transformation of Type II to Type I has a marked effect on the physical properties. For example, density, rigidity and strength are increased.
Unlike conventional polybutylenes, our unique elastomeric polybutylene crystallizes from melt in the form of crystal Type II, which is not distinctly transformed to crystal Type I over a period of hours or days. The physical properties of this type of elastomeric polybutylene (ELPB) made with SHAC™ 201 catalyst is significantly different from the polymer made from the conventional isotactic polybutylene (I-PB) with titanium trichloride (TICl 3 ) as catalyst and the short stereoblock polybutylene (SSPB) made with a SHAC™ 103 catalyst.
The novel elastomeric polybutylene can also be made with the catalyst system disclosed in U.S. Pat. No. 4,971,936. The catalyst comprises the reaction of a magnesium alkoxide and a tetravalent titanium halide wherein the reaction takes place in the presence of an electron donor which is selected from the group consisting of 3-methyl-veratrole, 3-methoxy-veratrole, 4-nitro-veratrole and 4-methoxy-veratrole.
Table 1 lists the general physical properties of the elastomeric polybutylene (ELPB) of this invention. Also shown in Table 1, for comparison, are corresponding properties of a butene-1 homopolymer (I-PB) produced on a commercial scale in a solution process with TIC13 as catalyst and those of butene-1 homopolymer (SSPB) with a SHAC™ 103 catalyst.
TABLE 1______________________________________COMPARISON OF ELPB, SSPB, AND I-PBPROPERTY ELPB SSPB* I-PB______________________________________Catalyst SHAC 201 SHAC 103 TiCl.sub.3% Isotacticity <70 71-80 >80Liso <20 <25 >85% Syndiotacticity** >10 5-10 <5Melting Point, °C.1st Heat <105 100-118 >1202nd Heat <101 98-110 >110% Crystallinity <25 25-40 >40Tensile Strength <3,000 3,000-4,500 >4,500@ Break psiElongation at >500 300-600 <400Break, %Yield Strength, psi No Yield 400-1,700 >1,700 PointTensile Set, % <170 150-200 >200______________________________________ *Data mostly from the U.S. Statutory Invention Registration No. H179.
As shown in Table, 1, the elastomeric polybutylene is very distinctly different from the other type polybutylenes in basic molecular configuration in such properties as tacticity, and isotactic block length (Liso). They are also different in physical properties such as melting points, percent (%) crystallinity, tensile break strength, elongation, tensile yield strength and percent (%) tensile set. The no tensile yield point and low tensile set of the elastomeric polybutylene is particularly suitable in applications pertaining to the replacement of PVC film as film wrap and in the manufacture of fibers where high resiliency is required.
The invention is further described by the following non-limiting examples and data tables.
EXAMPLE 1
Butene polymerizations were conducted in a one gallon stainless steel autoclave utilizing 1.7 liters of butene-1 monomer. The magnesium alkoxide compound of the formula:
Mg.sub.4 (OCH.sub.3).sub.6 (CH.sub.3 OH).sub.10 (1,3-0,OH-C.sub.6 H.sub.4).sub.2, M
(wherein (1,3-O,OH-C 6 H 4 ) 2 , M is a resorcinate) was used to prepare the procatalyst. The magnesium alkoxide compound was prepared by the dropwise addition of tetraethoxysilane stabilized 12% magnesium methoxide solution to a solution of resorcinol in methanol. Partial azeotropic desolvation was carried out by slurrying 40 grams of M in 300 grams of cyclohexane containing 120 grams of tetraethoxysilane and boiling the mixture until a decrease of 20 to 30% in solvent volume had occurred.
The procatalyst was prepared by stirring 7.8 grams of dissolved M with 12 mmoles of 4-methoxyveratrole in 200 ml of a 50-50 titanium tetrachloride-chlorobenzene solution for one hour at 115° C. followed by two washes at 115° C. with fresh 200 ml portions of that solvent mixture, then a quick rinse (less than 10 minutes) with 100 ml of fresh titanium tetrachloridechlorobenzene solvent mixture. Excess titanium was removed by thorough isopentane rinsing and the catalyst was dried under moving nitrogen at 40° C. Ti content was 3.55%. A portion of the dry procatalyst powder was then made into a 5% slurry in mineral oil.
In the following polymerizations, triethyl aluminum was used as a 0.28 molar in isooctane. Tiisobutyl aluminum was used as a 0.87 molar solution in heptane. Diethylaluminum chloride was used as a 1.5 molar solution in heptane.
The polymerization was carried out by mixing 0.015 to 0.003 mmol of procatalyst, aluminum alkyl, and selectivity control agent (SCA) then, after 20 minutes, injecting the mixture into 1.8 liters of liquid butene-1 in the one gallon stainless autoclave. At the end of 90 minutes the reactions were terminated by injecting 600 ml of isopropyl alcohol to the cooled reactor prior to venting the unreacted monomer. Additional details regarding the catalysts utilized is summarized in Tables IIA and IIB.
TABLE IIA______________________________________Catalysts With Substituted VeratroleAs Electron Donors Internal (SCA)Catalyst Electron Donor Mg Ti# Name Mmol % Wt % Wt______________________________________1 Vera 8.6 20.2 3.012 30 MV 10 17.9 5.783 40 MV 12 18.8 3.55______________________________________ Note: Vera = Veratrole 30 MV = 3 Methoxyveratrole 40 MV = 4 Methoxyveratrole
TABLE IIB______________________________________Autoclave Runs to Produce ELPB With Veratrole-BasedCatalysts (1.8 liters butene-1, 0.01-0.02 mol Ti, 60° C., 90min.) SCA/Ti TEA/Ti YieldRun # Cat. # SCA mol/mol mol/mol Kg/g cat.______________________________________1 1 CYANCL 4 105 8.02 2 DIBDMS 5 107 4.23 3 None -- 70 7.0______________________________________ NOTE: CYANCL = Cyanuric Chloride DIBDMS = Diisobutyl dimethoxysilane TEA = Titanium SCA = Selectivity Control Agent
The tensile data and NMR results are shown in Tables IIC and IID, respectively.
TABLE IIC______________________________________Tensile Data of the ELPB ProducedRun Tbreak Tset Tyield Elong.# psi % psi %______________________________________1 2751 162 No 4852 1932 166 Yield 3463A 1609 110 Point 5573B 100 600______________________________________
TABLE IID______________________________________NMR Result of the ELPB ProducedRun # ISO % Liso Units Syn %______________________________________1 68 17 132 64 16 143 60 10 16______________________________________
The low tensile set values and no yield point of the novel elastomeric polybutylene makes it suitable in film applications which requires good recovery upon stretch and in fiber applications which requires good recovery upon compression.
EXAMPLE 2
The ELPB product from run #3 in Example 1 was further characterized based on its physical properties. These properties are summarized in Table IIIA.
TABLE IIIA______________________________________Physical Properties of ELPB Product fromRun #3, Example 1______________________________________% Isotacticity 60Liso, Units 10% Syndiotacticity 16Melting Point, °C.1st Heat 101.52nd Heat 100.3% Crystallinity 20Tensile Strength at Break, psi 1609Elongation at Break, % 557 660Yield Strength No Yield PointTensile Set, % 110 120______________________________________
The ELPB because of its low tensile set and no tensile yield point is very suitable for the manufacture of wrapping films for fresh meat and produce and in fibers for carpets.
While this invention has been described in detail for the purpose of illustration, it is not to be construed as limited thereby but is intended to cover all changes and modifications within the spirit and scope thereof. | It is herein disclosed a novel elastomeric polybutylene-1 having and exhibiting syndiotacticity of greater than ten percent, and possessing other desirable properties.
The novel elastomeric polybutylene-1 can be blended with compatible materials such as polypropylene and its copolymers, ethylene-propylene block copolymers, butyl rubbers and polyisobutylene. Such compositions are particularly suitable in films, hot melt adhesives, textile and fiber applications.
The novel elastomeric polybutylene-1 can also be blended with incompatible materials such as ethylenically unsaturated esters (EVA, EMA, EMAA, EEA), polyester, nylon, polystyrene, styrene block copolymers (SEBS, SIS, SBS) and polyethylenes into a composition having soft and improved elastic properties. Such blends are particularly useful in easy-open packaging and foam applications, and in PVC replacement. When oriented, films made of such blends are used as soft and elastic shrink films.
The novel elastomeric polybutylene-1 can also be blended with both incompatible and compatible materials. | 2 |
BACKGROUND OF THE INVENTION
In new residential construction, most houses are built on a concrete slab foundation or on foundation walls. Typically, anchor or foundation bolts are placed in the wet concrete a minimum of six feet on center around at least the perimeter of the house. A wood sill is then used in conjunction with the anchor bolts to tie the house to the foundation by having the anchor bolts pass through corresponding openings through the wood sill.
In order to mark the location of the anchor bolts on the wood sill, the framer normally lays the wood sill on top of the bolts and hits the wood with the hammer to leave an imprint in the wood at the position of the anchor bolts. The framer will then drill the holes, build the wall section and hoist it over the bolts flush with the concrete. In accordance with model building codes, the holes should be no more than 1/16 of an inch larger than the bolts. In practice, framers often drill oversized holes so that it is easier to locate the wall on the bolts and then slam it down flush to the concrete. Then the framer puts a washer and a nut over the bolt and tightens them down to secure the wood sill, thereby securing the wall section to the foundation.
In an earthquake, the bolt to wood sill connection is supposed to restrain the house from shifting off the foundation. However, ground movement causes the anchor bolt to transfer the load to one edge of the hole thereby crushing the wood which could ultimately cause the wood to split. In addition, if the hole is oversized, the house may shift as much as 1/4" before the bolt begins to restrain movement but the house has already built up substantial momentum before it meets with the resisting side of the hole. Therefore, considerable damage can occur above and below the floor line even at very low quake levels. As a specific example, in a recent earthquake in the Big Bear area of California, there were a number of failures in newly constructed homes with oversized holes around the anchor bolts. Some of these homes slipped completely off their foundations and were a total loss.
SUMMARY OF THE INVENTION
The present invention provides for a wood sill reinforcement plate including a flat plate section having an opening just slightly larger than the diameter of the anchor bolt and a plurality of prong members which extend outward from the flat plate. The use of the present invention ensures that damage, and possible failure of a building structure, can be reduced by using the wood sill reinforcement plate to transfer the force from the anchor bolt through the reinforcement plate to the gripper prongs and down into the wood.
The wood sill reinforcement plate of the present invention may be used in a number of ways. First, the reinforcement plate can be placed on top of the wood sill around the anchor bolt to merely replace the washer that is normally used. This would be the least expensive way of using the present invention but it still allows the anchor bolt to bend through the opening in the wood sill before restraint by the reinforcement plate of the present invention.
A second way of using the reinforcement plate of the present invention is to place the reinforcement plate over the anchor bolt prong side up before the wall section is placed over the anchor bolts. The weight of the wall section will drive the prongs into the wood sill. A normal washer and nut would still be used at the top surface of the wood sill but the use of the reinforcement plate at the bottom position immediately transfers the load to restrain movement.
The best and most preferred use of the present invention is to place reinforcement plates on both the top and bottom positions of the wood sill surrounding the anchor bolt. This tightly restrains the anchor bolt and optimizes the load transfer from the house down to the foundation. Extensive developmental testing was performed on this device. In addition, eight series of three tests each were conducted according to the standards of the International Conference of Building Officials, the model code enforcement agency of the Uniform Building Code (used by all Western States). Anchor bolts were tested without the device and with the device on the top, the bottom, and on top and bottom. Both appropriately sized holes (1/32" larger than the bolt), and oversized holes (1/4" larger than the bolt) were tested.
Using the reinforcement plate of the present invention improved the ultimate bolt-to-wood connection by 15% when used on top, by 30 to 38% when used on the bottom and by 81-88% when used on the top and bottom. This suggests that the reinforcement plate is a powerful tool for reducing the ultimate failure of the sill plates.
An even more important finding was that there was a 150% to 300% improvement of the bolt-to-wood connection at low forces when the hole was oversized. This suggests that even in a minor quake, considerable cosmetic and some structural damage can be reduced by using the reinforcement plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(a), 1(b) and 1(c) illustrate a top and two side views of a first and preferred embodiment of the present invention,
FIGS. 2(a), 2(b) and 2(c) illustrates a top and two side views of the second embodiment of the invention,
FIGS. 3(a), 3(b) and 3(c) illustrates a top and two side views of a third embodiment of the invention,
FIGS. 4(a), 4(b) and 4(c) illustrates a top and two side views of a fourth embodiment of the invention,
FIG. 5 illustrates the invention used only on the top of the wood sill;
FIG. 6 illustrates the invention used only on the bottom of the wood sill; and
FIG. 7 illustrates the invention used both top and bottom of the wood sill.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIGS. 1(a), 1(b) and 1(c), a wood sill reinforcement plate includes a flat plate section 10 with an opening 12 extending through the plate 10 and having a diameter slightly larger than an anchor bolt to receive an anchor bolt. In addition, a plurality of gripper prongs 14 extend downward and are shown to be formed with a sharp point so as to pass into and grip the wood sill when the reinforcing plate of the present invention is installed in the construction of homes.
In FIGS. 2(a), 2(b) and 2(c) illustrate a second embodiment and has a flat plate portion 20 includes an opening 22. As can be seen, the opening 22 is actually formed with a tapered portion extending downward to have a lower portion 24 of approximately a size to receive the anchor bolt. The tapered portion forms a gripper surface to extend into any open area between the anchor bolt and the opening in the wood sill to fill the opening and to strengthen the corner providing additional reinforcement for the wood. The embodiment of FIG. 2 also includes gripper prongs 26 similar to the prongs 14 in FIG. 1.
FIGS. 3(a), 3(b) and 3(c) show yet another embodiment of the present invention including a plate portion 30 with an opening 32 to receive the anchor bolt. The plate 30 has slightly canted corners so that gripper prongs 34 have a slightly wider profile then the gripper prongs 14 and 26 of FIGS. 1 and 2 respectively. The gripper prongs 34 would thereby enter the wood at a slight angle across the grain increasing the drag through the wood and reducing the parallel tracking through the wood as occurs with the gripper prongs of FIGS. 1 and 2.
Finally, FIG. 4(a) , 4(b) and 4(c) illustrate a fourth embodiment of the invention which is essentially similar to the embodiment shown in FIG. 1 except that a plate member 40 has an elongated rectangular form. The plate 40 includes an opening 42 to receive the anchor bolt. A plurality of gripper prongs 44, which are six in number, extend downward and grip the wood in a similar manner to those shown in the embodiments of FIGS. 1, 2 and 3. Theoretically, the larger number of gripper prongs will spread the load even further into the wood sill in the event of an earthquake.
FIGS. 5, 6 and 7 illustrate the use of the wood sill reinforcement plate of the present invention and specifically illustrate this use with the embodiment of FIG. 1. The embodiment of FIG. 1 is the simplest in construction and the most inexpensive to manufacture, but depending upon specific applications, other embodiments such as shown in FIGS. 2, 3 and 4, may be desired for other applications. In normal practice, the embodiment of FIG. 1 is sufficient for most uses.
As shown in FIGS. 5, 6 and 7 a concrete foundation 50 extends under a house and with anchor bolts 52 set into the concrete approximately every six feet around the perimeter of the house in order to tie the house to the foundation through a wood sill 54. This is normal and typical construction for homes and the anchor bolts are normally placed in the concrete while wet for new construction but may be retrofit into existing homes using conventional techniques.
In order to mark the location in which to drill holes 56 through the wood sill 54, the framer normally lays the wood sill on top of the bolts 52 and bangs the wood plate 54 with a hammer so as to make an impression in the wood. The framer drills the holes 56 and then pushes the wood sill over the anchor bolts down onto the concrete foundation 50. As indicated above, the holes 56 should only be slightly larger, such as 1/16 inch larger than the bolts. In practice, the framers can drill oversized holes 56 so that it is easier to push the wood sill 54 through the bolts 52 and down to the foundation 50. In normal practice, a washer and nut such as shown by the washer 58 and nut 60 are used to lock the anchor bolt 52 to the wood sill 54. In the present invention, the nut 60 would still be used, but the washer 58 may be replaced with the reinforcing plate of the present invention.
As shown in FIG. 5, a single reinforcing plate 10 is used for each anchor bolt 52 and located only on the one upper side of the wood sill 54 to replace the washer 58. As can be seen in FIG. 5, the reinforcing plate 10 would be placed around the anchor bolt 52 and the gripper prongs 14 hammered into the wood normally with the prongs extending along in the same direction as the grain of the wood. The nut 60 is then tightened down on the bolt to lock the entire structure together.
It is to be appreciated that the use of the invention, as shown in FIG. 5, can enhance existing foundation bolting systems and retrofit installations. For example, if a home already has anchor bolts with nuts and washers, the washers can be removed and replaced with reinforcing plates as shown in FIG. 5. Or, the washer can be reinstalled over the plate rather than thrown away.
In FIG. 6 the reinforcing plate 10 may be positioned directly on the concrete and with the gripper prong members extending upward. After the wood sill 54 is positioned over the anchor bolts 52, the wood sill may be hammered down to have the prongs grip the wood. The construction could be finished off using the washer 58 and nut 60 as in the prior art.
As shown in FIG. 7, the ultimate application of the present invention is to place reinforcing plates 10 both on top and bottom of the wood sill 54 surrounding the anchor bolt 52. In this way, as the bolt 60 is finally tightened into position, the reinforcing plates of the present invention tightly restrain the bolt 52 and optimize the load transfer from the house down to the foundation. As indicated above, it has been determined that the use of the invention in such a preferred manner can increase the ultimate load that the anchor bolt can carry by up to an additional 88%.
The present invention therefore provides for a reinforcing plate which is inexpensive, easy to install and inspect. The present invention increase the critical bolt to wood connection. Unlike a standard washer, the load forces are transferred to the wood sill by gripper prongs at the corners of the reinforcing plate. Standard washers need to crush down into the wood to restrain whereas the present invention does not need to crush the wood since the gripper prongs transfer the load.
It is also to be appreciated that since the present invention provides for a better anchor bolt to wood connection, this means that the bolts may be spaced further apart if desired. This provides for an additional saving in the cost of labor to install all of the bolts. Another advantage of the present invention is that the invention improves all bolt to wood connections parallel to the grain of the wood. This therefore also includes products used to restrain uplift which is a problem in the connection of shear walls and vertical members.
It should be noted that if the reinforcing plate of the present invention is used only on the top of the wood sill plate to the washer, the bolt can still bend through the wood sill before restraint. This is the least expensive use of the present invention and is considerably better than only using a washer. On the other hand, if the reinforcing plate is used only on the bottom of the wooden sill, this at least immediately transfers the load to restrain the movement. However, a washer is still required on the top. Ideally, the present invention provides the ultimate benefit by being placed both on the top and bottom of the wood sill so as to tightly restrain the anchor bolt and optimize the load transfer from the house down to the foundation.
Although this invention has been disclosed and illustrated with reference to particular embodiments, the principles involved are susceptible for use in numerous other embodiments which will be apparent to persons skilled in the art. The invention is, therefore, to be limited only as indicated by the scope of the appended claims. | A wood sill reinforcing plate for use with anchor bolts embedded in a concrete foundation and extending upward and a wood sill having openings which receive the outwardly extending anchor bolts. A plate member having an opening extending through the plate member and with the opening having a dimension slightly larger than the diameter of the anchor bolt. A plurality of gripper prongs integral with the plate member and extending in a direction substantially perpendicular to the plate member for embedding the gripper prongs into the wood sill to lock the plate member around the anchor bolt with the anchor bolt extending through the opening in the plate member. | 4 |
BACKGROUND OF THE INVENTION
I. Field of the Invention:
This invention relates generally to a method and apparatus for processing materials, such as semicoductor devices in a vacuum environment, and more particularly to an improved processing method and apparatus whereby low yields due to contamination are overcome.
II. Discussion of the Prior Art:
In fabricating integrated circuit chips, a wafer of semiconductor materials, such as silicon or gallium arsonide, are subjected to a sequential series of processing steps, including oxidation, dopant diffusion by ion implantation, masking and etching, metal depositions, further depositions of insulating materials, such as silicon oxide, in the formation of various junctions and interconnects including terminal pads and the like. The silicon wafer is then tested and ultimately sliced into discrete integrated circuit chips before the chips are individually encased in a suitable package. The aforementioned steps of metallization, passivation, etc., must be carried out in an extremely clean environment. Semiconductor production facilities commonly include so-called "clean rooms" in which the room air is filtered and exchanged at high flow rates and workers are gowned in relatively dust-free clothing. These ultra-clean production environments are mandated when it is considered that even the tiniest of foreign contaminants can result in a defective semiconductor device.
As indicated above, various metallization and passivation steps performed on the silicon wafers are carried out in a vacuum using vacuum deposition and vacuum sputtering techniques. Typically, during a metallization step, one or more semiconductor wafers are placed in a vacuum chamber which may be pumped down to a pressure of -5×10 -6 torr and then the metal, typically aluminum, contained in a fixture is exposed to a high energy electron beam and caused to vaporize. The vapors are allowed to condense on the silicon substrate, and then the metal layer is later etched, in the vacuum chamber by a reactive sputtering process or otherwise, in accordance with a predetermined pattern defined by a photoresist layer which has been exposed to light through one or more masks. More than one such metallization step is usually required.
In a subsequent step, the metallized and etched wafer may be placed in still another vacuum chamber in which silicon oxide (glass) is deposited so as to create an insulating passivation layer.
A typical vacuum system to provide a local gaseous environment for use in semiconductor manufacture would typically include a process chamber having entrance and exit locks, a vacuum pump providing a means for evacuating the gaseous content of the process chamber as well as the load lock and exit lock thereto, an on/off vent valve which allows control of the vacuum displacement with a desired gas and also a on/off vacuum valve for controlling the evacuation of the process chamber by means of the vacuum pump.
The standard operation of the vacuum valve and the vent valve in a typical prior art vacuum deposition system creates a pressure "burst" when either pumping the system to a predetermined vacuum or when venting the system to atmosphere, such as occurs prior to the loading and unloading of products into and from the vacuum chamber. I have found that this pressure burst will disturb and redistribute contamination that resides within the process chamber. The contamination typically comprises minute, microscopic particles which have remained in the processing chamber following previous runs of product through that chamber. For example, after only a few cycles of operation, the vacuum metallization chamber collects a residue of metal or metallic oxides which come to rest on the fixtures contained within the vacuum chamber. Similarly, in the glass passification step, minute particles of silicon oxide can collect on the surfaces of the vacuum chamber used for that operation, later to become shaken free due to the rush or burst of gas movement when the pressure in the chamber or the locks leading thereto is suddenly changed. This redistribution of contamination can and often does result in decreased process and product yield, which, in turn, reflects a loss of profit dollars.
OBJECTS
It is accordingly a principal object of the present invention to obviate the above-described shortcomings of the prior art vacuum based manufacturing processes.
Another object of the invention is to provide an apparatus and method for substantially eliminating redistribution of contaminants within a vacuum processing chamber during the pump-down and subsequent venting of that chamber.
Yet another object of the invention is to provide a method and apparatus for improving the yield of product produced using vacuum processing techniques.
A still further object of the invention is to provide a cost-effective device to eliminate pressure bursts from defect-sensitive processing of workpieces, such as semiconductor wafers, in a vacuum environment.
SUMMARY OF THE INVENTION
A conventional vacuum processing system includes a system chamber having a load door through which product to be treated may be inserted and removed. The door is surrounded by a gastight seal. Suitable tubes or lines are provided for coupling the processing chamber to a vacuum pumping station and a main vacuum gate valve is disposed in that line so that once the chamber is pumped down to a suitable negative pressure, the valve can be closed to retain that pressure. At other times, this valve may also be left open during some processes to allow continued flow across the product. A vent line having a vent valve disposed therein joins the system vacuum chamber to a source of suitable vent gas so that, following the completion of the processing step within the vacuum chamber, that vent valve may be opened to allow the vent gas to be drawn into the evacuated system chamber to restore the interior of the chamber to atmospheric pressure.
In accordance with the present invention, there is placed in parallel with the main vacuum gate valve, a motor-driven, variable-orifice valve such as a needle valve. The motor is controlled by an electronic circuit so that it can be made to open and close in accordance with a predetermined time profile. For example, the drive motor control circuit may provide an adjustable "turn-on" ramp as well as an adjustable total flow "set-point". Those valves in the system of the present invention, which are designed to go from a closed flow condition to an open flow condition over a predetermined time interval, will be referred to herein as "soft-start valves" or by the acronym "SSV".
When it is desired to evacuate the system, the main vacuum gate valve is originally closed, as in the SSV. If the SSV does not possess a positive shut-off characteristic, it is expedient to use a positive shut-off valve in series with it. Valves having a positive shutoff capability are commercially available. The control signal commanding the vacuum gate valve to open so as to expose the interior of the processing chamber to the continuously running vacuum pump is delayed while the series shut-off valve, if used, is immediately driven to its opened condition. The SSV will begin to slowly "ramp" open at the preselected rate and to the preselected set-point. Only after this set-point is reached will the vacuum gate valve respond to the delayed command signal. Thus, the interior of the processing chamber is not instantaneously exposed to a maximum negative pressure which would otherwise tend to cause the contaminants contained therein to be disturbed and redistributed. When the main vacuum gate valve is commanded to close, both the SSV and the optional shut-off valve may be simultaneously closed or, alternatively, the SSV may also be allowed to close in a slow "ramped" mode followed by the delayed closure of the series shut-off valve.
In applying the present invention to the vent side of the processing chamber, an SSV is placed directly in series with the main vent valve and is arranged to be closed whenever the main vent valve is closed. The main vent valve can also be totally eliminated from the system if the particular SSV selected has a positive shut-off capability. However, assuming that the SSV does not have a positive shut-off capability and is in series with the main vent valve, when the main vent valve is commanded to open, the SSV does not open instantaneously, but instead opens in accordance with the ramp-up profile established by its associated motor control circuit. As such, a sudden rush or burst of vent gas into the processing chamber is avoided. When the main vent valve is commanded to close, the SSV under control of the motor control will close with a predetermined "ramp" and then will give the series valve a delayed close signal. Thus, the vent gas used to bring the interior of the vacuum chamber up to atmospheric pressure is introduced and stopped at a slow, programmed rate and, as such, does not tend to blast debris contained within the vacuum chamber loose, allowing it to settle upon the workpiece being processed in the vacuum chamber.
The foregoing advantages, features and objects of the invention will become apparent to those skilled in the art from the following detailed description of a preferred embodiment, especially when considered in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a family of curves showing the manner in which the yield of satisfactory integrated circuit chips varies as a function of defect density;
FIG. 2 is a schematic diagram of a vacuum processing system incorporating the present invention;
FIG. 3 is a block diagram of the motor control circuit shown in the drawing of FIG. 1;
FIGS. 4(a) and 4(b) show the comparative flow profiles of the vent valve operations when the present invention is used and not used, respectively; and
FIGS. 5(a) and 5(b) show the comparable flow profiles as those in FIGS. 4(a) and 4(b) for the vacuum side of the system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There are typically three chip failure modes associated with contamination:
1. Short circuits caused by "bridging" of circuit features.
2. Open circuits caused by "masking" of circuit features.
3. Lifetime failures caused by "partial" opens and shorts that mature as a result of electrical, mechanical or temperature stresses.
Referring to FIG. 1, there is plotted a family of curves in accordance with the well-accepted Murphy yield model reflecting, for the semiconductor industry generally, the yield of acceptable chips as a function of the number of defects per square centimeter for chips of varying size. These curves reveal that for any type of flaw or contamination large enough to cause an "open" or "short" in the circuit, as the number per square centimeter increases, the yield of operational chips decreases quite rapidly toward zero. The yield graph shows decreasing yields for increasing die area. This is due to the fact that as chip area increases, the probability of including a defect into that area increases. An additional impact on yield is that as geometrics shrink, probability of a given contaminate size causing a failure increases as well.
Thus, it is apparent that, to increase the yield of usable product, it is imperative that the incidences of defects due to contamination should be kept to an absolute minimum. As already pointed out in the introductory portion of this specification, I have found that one commonly overlooked source of contamination is the debris remaining within the vacuum chamber following its use for the batch or serial processing of semiconductor wafers. A typical vacuum system used in processing semiconductor wafers in the formation of integrated circuits is illustrated schematically in FIG. 2. Here, the system is indicated generally by numeral 10 and is seen to include a vacuum chamber 12 having an access door 14 for allowing workpieces to be inserted and removed. A vacuum line 16 leading to a continuously-running vacuum pump 17 is joined to the vacuum chamber 12, and disposed in the line 16 is a vacuum gate valve V 3 . This valve is typically an air-operated valve that, upon receipt of an electrical on/off signal, assumes a full media-passing or a full media-blocking position. The term "media" is intended to include gases as well as gases containing solid particles.
A typical prior art vacuum processing system also includes a vent line 18, which is arranged to be coupled to a source of vent gas (not shown) and which leads to the vacuum chamber 12. Disposed in series with the line 18 is a pressure regulator 20 and a vent valve V 1 , the latter typically being an air-operated bang-open/bang-close type of valve and is actuated by an electrical on/off "vent" command originating at the system process controller (not shown).
With regard to the vacuum processing system thus far described, when it is desired to perform a process step in vacuum, the door 14 to the vacuum chamber 12 is open and the workpiece is situably positioned in a holding fixture contained within the vacuum chamber. The door is then reclosed and sealed. The vent valve V 1 at this time is closed and, when the vacuum valve V 3 is commanded to open by an electrical signal from the system process controller, the valve V 3 opens relatively instantaneously exposing the interior of the vacuum chamber to the negative pressure provided by the vacuum pump 17 joined to the vacuum line 16. This sudden application of a negative pressure has been found to disturb particulate matter residing within the interior of the vacuum chamber 12 from previous processing cycles and this debris can settle upon the workpiece to be treated, resulting in its contamination.
Once the processing step has been completed, the valve V 3 is "bang" closed while the vent valve V 1 is commanded to "bang" open. The sudden exposure of the interior of the vacuum chamber 12 to atmospheric pressure is, of course, accompanied by an in-rush of vent gas which typically might be nigrogen, argon or helium depending upon the nature of the manufacturing process being effected. This in-rush of gas into the vacuum chamber 12 tends to again shake minute particles of foreign materials loose from the interior walls and surfaces of the chamber 12 itself, as well as from the fixtures which may be contained therein. This foreign matter routinely settles upon the workpiece prior to its removal from the chamber 12 via the chamber's entry/exit door 14.
To obviate this problem and to thereby increase the yield of usable product resulting from the vacuum processing operations, I have added to the prior art system described above the apparatus shown as being enclosed by the broken line boxes 22 and 24. As is illustrated, there is provided a by-pass line 26 connected in parallel with the bang open-bang close vacuum valve V 3 and included in the branch 26 is a soft-start, motor-operated variable orifice valve SSV 4 . Also shown enclosed by the broken line box 22 is a motor 28 whose shaft is suitably coupled to the valve SSV 4 , the motor being controlled by a control circuit 29, the particulars of which will be described hereinbelow in connection with FIG. 3. In implementing the invention, I have used a Type 1624 Micro-Mo motor whose shaft is coupled to the variable orifice valve SSV 4 . A valve suitable for use in this application may be a Nupro Type SS-4BMG although other models also available from Nupro may be used as well and may include a positive shut-off capability. The motor control circuits 29 and 30 are each arranged to provide a predetermined flow versus time profile through the valves SSV 2 and SSV 4 . In this regard, reference is now made to FIG. 3 which shows a schematic diagram of the motor control circuits.
Each of the motor control circuits 29 and 30 used in the system of FIG. 2 can be considered as comprised of two major subassemblies, namely, a voltage regulator circuit 38 and a dc servo motor controller/driver circuit 40. A one-shot based time delay circuit 36 is also utilized with the vent valve V 1 and the vacuum valves V 3 shown in FIG. 2.
The voltage regulator 38 is illustrated as a solid-state, three-terminal device, and preferably may be a Type LM317 integrated circuit voltage regulator chip 39 which receives an unregulated DC voltage at its input terminal 42 and produces a steady, regulated voltage at its output terminal 44, the magnitude of which can be set by potentiometer 46. Capacitors 48 and 50 provide ripple filtering.
The signal V adj appearing at terminal 44 is, in turn, supplied to the servo motor controller driver 40 in a manner yet to be described. The voltage regulator circuit 38 also includes a second three-terminal integrated circuit regulator chip 52 for providing a steady, well-regulated direct current bias signal V+ which, too, is utilized by the servo motor controller driver circuit 40 and the delay circuit 38. To eliminate unnecessary lines in the drawings, the conductors connecting the output from the voltage regulators 39 and 52 to the remainder of the circuit have been eliminated, it being understood that the terminals of the circuit labeled V adj and V + are connected to the correspondingly labeled terminals of the voltage regulators 39 and 52.
The time delay circuit 36 includes a precision timer integrated circuit 54 which may, for example, be a Type ICM7242, which is configured as a one-shot circuit. Coupled between the voltage reference source V + and pins 7 and 1 thereof is a RC timing circuit including capacitor 56 and a variable resistor 58 which together determine the delay period of the precision timer.
The trigger signal for the timer is derived from the "Valve Open" or the "Valve Close" control signal applied to input 60 from the system control panel (not shown). This signal is a binary "Hi" on the "Open" command and a binary "Lo" for the "Close" command. In either event, it is coupled through a current limiting resistor 62 to the non-inverting input of an op amp buffer inverter 64 and to the inverting input of a similar op amp inverting buffer 66. A source of reference potential is applied to the remaining inputs of each of these buffers from the center terminal 68 of a resistive voltage divider including the series resistors 70 and 72 connected between V + and ground. The output from the two buffer inverters 64 and 66 are wire OR'ed together at 74, such that on either command, a binary Hi signal results and when the jumper is connected between terminals A and C as shown, this Hi input is capable of triggering the delay one-shot comprised of the IC timer 54 and its associated RC timing network which includes the resistor 73 and the capacitor 75. The output on pin 3 of circuit 54 is normally Hi and goes Lo for the period of the timer established by the RC components 56 and 58.
A further inverter 76 having an open collector output to accommodate a range of logic voltage levels and a jumper selectable option feature allows the "Delay Out" signal to be selectively either a Hi or Lo condition to accomodate the downstream logic. More particularly, the output from pin 3 is resistor AND'ed at 78 with the trigger signal and, when the jumpers are connected as shown, the delay output signal will be Hi whereas if the jumpers are reversed, the Delay Out will be Lo.
The Value Open/Value Close commands, irrespective of polarity, appear at junction 74 and are applied to a dc servo motor controller chip 80 which preferably is a Motorola Type MC33030 device. It is a dc servo motor controller designed to provide all active functions necessary for a complete, closedloop system. As is pointed out in the Motorola Corporation Advance Information publication ADI 1154Rl, the MC 33030 dc servo motor controller provides all of the active functions necessary for a complete, closed-loop system. The device consists of an on-chip operational amplifier and window comparator with wide input common-mode range, drive and brake logic with direction memory, power H switch driver capable of handling 1.0 ampere, independently programmable over-current monitor and shut-down delay, as well as an over-voltage monitor. The over-current monitor is designed to distinguish between motor start-up and a locked motor condition that occurs when the actuator being driven by the motor reaches a travel limit. A fraction of the power H-switch source current is internally fed into one of the two inverting inputs of the current comparator, while the non-inverting input of the comparator is driven by a programmable current reference. The reference level is controlled by the component values of the resistor 82 connected to the R oc input pin (pin 15) of the MC 33030 IC chip. During an over-current condition, the comparator will turn off and allow the current source to charge the delay capacitor 84. When the charge across capacitor 84 reaches approximately 7.5 volts, the set input of an over-current latch contained within the IC chip goes high, disabling the drive and brake functions of the power H-switch. Thus, when the motor control valve SSV 4 or SSV 2 is to be driven open, the motor 28 or 32 is driven until the valve stem reaches its travel limit to the full-open position and, as the motor attempts to drive it further, its shaft stalls, creating the over-current condition which results in the drive being removed from the motor. Similarly, when the valve is being driven from a full open to a full closed position, the over-current condition arises when the valve becomes fully seated.
Because the Type 33030 integrated circuit chip normally responds to overcurrent conditions in the 100 milliamp range and because the motors used with the valves in the present invention do not draw stalled rotor currents in this high of a range, the chip has been adapted to the particular application by including the parallel combination of resistor 86 and capacitor 88 which is connected between system ground identified by the symbol 90 and the GND pins 4, 5, 12 and 13 of the device 80. The voltage developed across the RC circuit is amplified by cascaded amplifier stages 92 and 94 and the resulting amplified output is applied to the noninverting input of an op amp comparator 96. The threshold for the op amp 96 is set by the potentiometer 98 which is connected in series with a fixed resistor 100 between the reference source V+ and ground. When the amplified signal derived from the RC circuit 88 exceeds the threshold established for the comparator 96, the capacitor 84 will begin to charge and when the voltage across the capacitor reaches the 7.5 volt threshold associated with the controller/driver chip 80, the drive will be removed from the motor terminal pins 10 and 14. The potentiometer 102 allows the response time of the over-current sensing to be varied.
Having described the physical or structural aspects of the preferred embodiment, attention will next be given to its mode of operation.
OPERATION
At the start of a vacuum processing operation, the interior of the vacuum chamber 12 will be at atmospheric pressure and the door 14 may be opened to insert the device to be worked upon. When the door 14 is closed and sealed, the vent valve V 1 and the soft-start valve SSV 2 in the vent line 18 will be closed. Furthermore, the main vacuum valve V 3 as well as the soft-start valve SSV 4 will also be closed. Upon receipt of the "PUMP" control command from the system control panel (not shown), the signal to the motor control circuit 29 causes the motor 28 to open the valve SSV 4 in accordance with the flow versus time profile curve as previously explained. Because of the time delay circuit 36 embodied in the SSV control circuit 29, the main vacuum gate valve V 3 does not open until the ramp-up period of the soft-start valve SSV 4 has ended and it is fully opened. It can be seen, then, that the interior of the vacuum chamber 12 will not instantaneously be subjected to the full negative pressure of the vacuum source, but instead, will slowly draw the gas contained within it through the vacuum line 16, via the by-pass line 26 to the continuously running vacuum pumping station.
When the signal from the system control panel commands the vacuum gate valve V 3 to close, it closes immediately, while the motor 28, under control of the motor control circuit 29, will again drive the valve SSV 4 to its closed condition in accordance with a predetermined ramp-closed profile. If the valve SSV 4 does not have a positive shut-off capability, an air or solenoid operated bang open/bang close valve can be placed in series with the valve SSV 4 but caused to open or close as the case may be only after the delay period has elapsed.
In a typical vent phase of operation, an electrical signal from the process control panel is used to command the main vent valve V 1 to open. This same signal is applied to the motor control circuit 30 and it begins to function so as to apply a ramp voltage to the motor 32 such that the soft-start valve SSV 2 will be driven open to its predetermined set-point flow condition over a predetermined time span. As such, the vent gas from the vent gas supply (not shown) is allowed to flow into the vacuum chamber 12 in accordance with the profile established by SSV 2 . This reduces or eliminates the shock which would otherwise be experienced within the vacuum chamber if a full in-rush of vent gas were permitted to flow through the system's main vent valve V 1 .
It can thus be seen that there is provided by this invention a control mechanism for the vacuum processing chamber 12 whereby sudden pressure bursts within the chamber are avoided during the pump-down and venting cycles. This has been found to markedly reduce the incidents of defects in the workpieces being processed and does not materially increase the amount of time required to complete the processing operation.
Those skilled in the art will recognize that various changes and modifications may be made to the preferred embodiment described herein. For example, it is recognized that if the vent valve V 1 were itself a variable orifice valve, such as a needle valve, a ball valve, a butterfly valve, or a gate valve, it could be directly operated by a motor in the same fashion that the valve SSV 2 is made to operate. This would eliminate the need for a separate, series-connected, soft-start valve. However, since all of the prior art systems of which I am aware incorporate an air-operated "bang" valve V 4 in the vent line 18, it has been found more convenient to add a separate soft-start valve in series with it.
Another alternative is to insert the soft-start valve SSV 4 in series with the vacuum valve V 3 rather than in parallel as shown. Then, in response to the "pump" command, the gate valve V 3 opens immediately while the valve SSV 4 slowly opens in accordance with a predetermined time profile. When shutting off the line to the vacuum pump 17, the valve SSV 1 is driven closed slowly, followed by the closure of the gate valve V 3 after a predetermined time delay established by delay circuit 36. If the valve SSV 4 has a positive shut-off capability and can be fully opened and fully closed in accordance with the programmed rate, then the gate valve V 3 could also be eliminated.
This invention has been described herein in considerable detail in order to comply with the Patent Statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to equipment details and operating procedures, can be accomplished without departing from the scope of the invention itself. | A method and apparatus for reducing the incidence of product contamination during processing of the product in a vacuum chamber. By providing soft-start valves in the vacuum and vent lines, and by properly driving said soft-start valves, it is possible to reduce the gas flow rates from and into the vacuum chamber to such a low level, that dust-like particles remaining in the chamber from prior product processing steps is not disturbed and allowed to settle upon the product then being treated. | 8 |
FIELD OF THE INVENTION
The present invention relates to the filed of organic synthetic intermediate preparative technology, and in particular, to a 2-substituted-2H-1,2,3-triazole derivative and its preparation method.
BACKGROUND OF THE INVENTION
The 2-substituted-2H-1,2,3-triazole derivative is a new type of compound having huge development value. A compound with triazole as mother nucleus has extensive potential application value, which is an important intermediate of compounds such as many drugs, herbicide and insecticide etc available at present, which is also a primary pharmacophore in a great many drug molecules.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a new type of 2-substituted-2H-1,2,3-triazole derivative and its preparation method.
In order to achieve the aforementioned inventive object, the present invention adopts the technical solutions as follows:
The present invention provides a 2-substituted-2H-1,2,3-triazole derivative, the 2-substituted-2H-1,2,3-triazole derivative has the following structure:
wherein R represents alkyl, aryl, aralkyl, cycloalkyl, cycloalkyl alkyl, heteroaryl, heteroaryl alkyl, heterocyclic alkyl; X represents chlorine, iodine.
Wherein when X in the formula 1 is chlorine, the 2-substituted-2H-1,2,3-triazole derivative is 2-substituted-4-bromo-5-chloro-1H-1,2,3-triazole shown in the following formula IV
wherein R represents alkyl, aryl, aralkyl, cycloalkyl, cycloalkyl alkyl, heteroaryl, heteroaryl alkyl, heterocyclic alkyl.
Wherein when X in the formula I is iodine, the 2-substituted-2H-1,2,3-triazole derivative is 2-substituted-4-bromo-5-iodo-1H-1,2,3-triazole shown in the following formula V
wherein R represents alkyl, aryl, aralkyl, cycloalkyl, cycloalkyl alkyl, heteroaryl, heteroaryl alkyl, heterocyclic alkyl.
A preparation method of the aforementioned 2-substituted-2H-1,2,3-triazole derivative, comprises the following steps:
dissolving the compound shown in the following formula III in mass to volume ratio of 1:2˜20 of diethyl ether, tetrahydrofuran or 1,4-dioxane or methyltetrahydrofuran, cooling to −78˜0° C., adding isopropylmagnesium chloride or isopropylmagnesium chloride-lithium chloride composite, stirring for 0.5˜2 hours, inleting chlorine or adding N-chlorosuccinimide, 1,3-dichloro-5,5-dimethylhydantoin, or adding iodine, stirring for 5˜30 minutes, heating up to room temperature, extracting by using organic solvent after quenching by using saturated ammonium chloride aqueous solution, drying via anhydrous sodium sulfate or anhydrous magnesium sulfate, concentrating to dry under reduced pressure, recrystallizing the obtained concentrate to obtain the 2-substituted-2H-1,2,3-triazole derivative;
wherein R represents alkyl, aryl, aralkyl, cycloalkyl, cycloalkyl alkyl, heteroaryl, heteroaryl alkyl, heterocyclic alkyl.
Specifically, the molar ratio of the compound shown in formula III to isopropyl magnesium chloride or isopropylmagnesium chloride-lithium chloride composite is 1:0.8˜1.5, the molar ratio of the compound shown in formula III to chlorine or N-chlorosuccinimide, 1,3-dichloro-5,5-dimethylhydantoin, iodine is 1:1˜10, the organic solvent is one of or a mixture of two or more than two, in arbitrary proportion, of fatty acids esters or ethers, including one of or a mixture of two or more than two, in arbitrary proportion, of ethyl formate, propyl formate, butyl formate, methyl acetate, ethyl acetate, propyl acetate, butyl acetate, isopropyl acetate, isobutyl acetate, amyl acetate, isoamyl acetate, methyl propionate, ethyl propionate, propyl propionate, butyl propionate and amyl propionate, diethyl ether, propyl ether, isopropyl ether, methyl tertiary butyl ether.
The present invention also provides another kind of 2-substituted-2H-1,2,3-triazole derivative, the 2-substituted-2H-1,2,3-triazole derivative has the following structure:
wherein R represents alkyl, aryl, aralkyl, cycloalkyl, cycloalkyl alkyl, heteroaryl, heteroaryl alkyl, heterocyclic alkyl; Y represents chlorine.
Preferably, the 2,4-disubstituted-2H-1,2,3-triazole derivative is 2-substituted-5-chloro-1H-1,2,3-triazole-4-carboxylic acid of formula VI
wherein R represents alkyl, aryl, aralkyl, cycloalkyl, cycloalkyl alkyl, heteroaryl, heteroaryl alkyl, heterocyclic alkyl.
A preparation method of another kind of 2-substituted-2H-1,2,3-triazole derivative, comprises steps:
dissolving the compound shown in the following formula III in mass to volume ratio of 1:2˜20 of diethyl ether, tetrahydrofuran or 1,4-dioxane or methyltetrahydrofuran, cooling to −78˜0° C., adding isopropylmagnesium chloride or isopropylmagnesium chloride-lithium chloride composite, stirring for 0.5˜2 hours, inleting chlorine or adding N-chlorosuccinimide, 1,3-dichloro-5,5-dimethylhydantoin, stirring for about 5˜30 minutes, heating up to room temperature, extracting by using organic solvent after quenching by using saturated ammonium chloride aqueous solution, drying via anhydrous sodium sulfate or anhydrous magnesium sulfate, concentrating to dry under reduced pressure, recrystallizing the obtained concentrate to obtain 2-substituted-4-bromo-5-chloro-1H-1,2,3-triazole of formula IV
wherein R represents alkyl, aryl, aralkyl, cycloalkyl, cycloalkyl alkyl, heteroaryl, heteroaryl alkyl, heterocyclic alkyl;
dissolving the compound shown in formula IV in mass to volume ratio 1:2˜20 of diethyl ether, tetrahydrofuran, methyltetrahydrofuran or 1,4-dioxane, cooling to −20˜30° C., adding isopropylmagnesium chloride-lithium chloride composite, stirring for 0.5˜5 hours, cooling to −50˜20° C., inleting carbon dioxide gas for about 10˜30 minutes, heating up to room temperature, extracting by using organic solvent after adjusting pH=1˜5 by using hydrochloric acid, drying via anhydrous sodium sulfate or anhydrous magnesium sulfate, concentrating to dry under reduced pressure, recrystallizing the obtained concentrate to obtain the 2-substituted-2H-1,2,3-triazole derivative.
Wherein the molar ratio of the compound of formula III to isopropyl magnesium chloride or isopropylmagnesium chloride-lithium chloride composite is 1:0.8˜1.5, the molar ratio of the compound of formula III to carbon dioxide is 1:1˜10, the organic solvent is one of or a mixture of two or more than two, in arbitrary proportion, of fatty acids esters or ethers, including one of or a mixture of two or more than two, in arbitrary proportion, of ethyl formate, propyl formate, butyl formate, methyl acetate, ethyl acetate, propyl acetate, butyl acetate, isopropyl acetate, isobutyl acetate, amyl acetate, isoamyl acetate, methyl propionate, ethyl propionate, propyl propionate, butyl propionate and amyl propionate, diethyl ether, propyl ether, isopropyl ether, methyl tertiary butyl ether.
The equations of the aforementioned preparation method of the 2-substituted-2H-1,2,3-triazole derivative provided by the present invention are shown as follows:
Isopropylmagnesium chloride or isopropylmagnesium chloride-lithium chloride composite of the present invention is different molar concentration of tetrahydrofuran solution, 2-methyl tetrahydrofuran solution or diethyl ether solution thereof, which commercially available concentration is usually 1.0˜2.0 mole/litre.
The molar ratio of the compound shown in formula III or the compound shown in formula IV to isopropylmagnesium chloride or isopropylmagnesium chloride-lithium chloride composite is 1:08˜1.5, preferably is 1:08˜1.2.
The molar ratio of the compound shown in formula III to chlorine or N-chlorosuccinimide, 1,3-dichloro-5,5-dimethylhydantoin, iodine or carbon dioxide is 1:1˜10, preferably is 1:2˜5.
The method of the recrystallizing includes the following steps: adding the concentrate in solvent according to mass to volume ratio of 1:1˜100, stirring for 0.5˜24 hours at −20˜50° C., filtering, vacuum drying, obtaining a pure product.
The solvent is one of or a mixture of two or more than two, in arbitrary proportion, of water, alcohols, fatty acids esters, ketones, ethers and hydrocarbons, including one of or a mixture of two or more than two, in arbitrary proportion, of methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropanol, n-butyl alcohol, tert-butanol, ethyl formate, propyl formate, butyl formate, methyl acetate, ethyl acetate, propyl acetate, butyl acetate, isopropyl acetate, isobutyl acetate, amyl acetate, isoamyl acetate, methyl propionate, ethyl propionate, propyl propionate, butyl propionate and amyl propionate, acetone, 2-butanone, cyclopentanone and cyclohexanone, diethyl ether, propyl ether, isopropyl ether, methyl tertiary butyl ether and tetrahydrofuran, 1,4-dioxane, petroleum ether, n-hexane, cyclohexane, methylcyclohexane and n-heptane. Preferably is a mixed solvent of methyl tertiary butyl ether and n-hexane, or isopropanol and water in arbitrary proportion.
The preparation method of the 2,4-disubstituted-2H-1,2,3-triazole derivative of the present invention is simple and feasible while the yield of the obtained compound is high.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention will be further explained below in combination with specific examples.
EXAMPLE 1
3.0 g (12.45 mmol) of 2-methyl-4,5-dibromo-2H-1,2,3-triazole was dissolved in 25 ml of tetrahydrofuran, cooled to −20˜−10° C., 6.85 ml (13.7 mmol) of 2.0M isopropylmagnesium chloride tetrahydrofuran solution was added dropwise slowly over 30 minutes. Once the dropwise addition was completed, stirring was continued for 30˜60 minutes. Chlorine was inleted slowly until reaction liquid was no longer heating up. Reaction liquid was added by 20 ml of saturated ammonium chloride aqueous solution, extracted using 30 ml of methyl tertiary butyl ether, dried by anhydrous sodium sulfate, and wasw concentrated to dry under reduced pressure. The residual solid was added by 20 ml of methyl tertiary butyl ether/n-hexane (⅕), heated to reflux for 1 hour, cooled to 0˜10° C., continued to be stirred for 1 hour, filtered, vacuum dried under a temperature <40° C. 2.06 g of 2-methyl-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, and the yield was 85%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.15 (s, 3H); 13 C NMR (CDCl 3 , 400 MHz): δ 137.0, 120.8, 43.1.
EXAMPLE 2
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 3.17 g (12.45 mmol) of 2-ethyl-4,5-dibromo-2H-1,2,3-triazole. 2.33 g of 2-ethyl-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 89%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.40 (q, J=7.2 Hz, 2H), 1.54 (t, J=7.2 Hz, 3H); 13 C NMR (CDCl 3 400 MHz): δ 136.7, 120.5, 51.7, 14.5.
EXAMPLE 3
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 3.35 g (12.45 mmol) of 2-n-propyl-4,5-dibromo-2H-1,2,3-triazole. 2.52 g of 2-n-propyl-4-bromo-5-chloro-2H-1,2,3-triazole oily matter was obtained, the yield was 90%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.30 (t, J=7.2 Hz, 2H), 1.99-1.93 (m, 2H), 0.93 (t, J=7.2 Hz, 3H); 13 C NMR (CDCl 3 , 400 MHz): δ 136.7, 120.5, 58.2, 22.9, 10.9.
EXAMPLE 4
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 3.50 g (12.45 mmol) of 2-cyclopropyl methyl-4,5-dibromo-2H-1,2,3-triazole. 2.71 g of 2-cyclopropyl methyl-4-bromo-5-chloro-2H-1,2,3-triazole oily matter was obtained, the yield was 92%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.18 (d, J=7.6 Hz, 2H), 1.40-1.33 (m, 1H), 0.67 (m, 2H), 0.43 (m, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 136.8, 120.6, 61.3, 10.8, 4.0.
EXAMPLE 5
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 3.67 g (12.45 mmol) of 2-cyclobutyl methyl-4,5-dibromo-2H-1,2,3-triazole. 2.84 g of 2-cyclobutyl methyl-4-bromo-5-chloro-2H-1,2,3-triazole oily matter was obtained, the yield was 91%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.34 (d, J=7.2 Hz, 2H), 2.93-2.85 (m, 1H), 2.11-2.04 (m, 2H), 1.95-1.78 (m, 4H); 13 C NMR (CDCl 3 , 400 MHz); δ 136.7, 120.5, 61.2, 35.0, 25.6, 18.1.
EXAMPLE 6
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 3.67 g (12.45 mmol) of 2-cyclopentyl-4,5-dibromo-2H-1,2,3-triazole. 2.87 g of 2-cyclopentyl-4-bromo-5-chloro-2H-1,2,3-triazole oily matter was obtained, the yield was 92%. 1 H NMR (CDCl 3 , 500 MHz): δ 4.94-4.4.88 (m, 1H), 2.18-2.13 (m, 4H), 1.92-1.84 (m, 2H), 1.73-1.66 (m, 2H); 13 C NMR (CDCl 3 , 500 MHz) δ 136.3, 120.1, 67.9, 32.6, 24.2.
EXAMPLE 7
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 3.87 g (12.45 mmol) of 2-(tetrahydrofuran-3-methyl)-4,5-dibromo-2H-1,2,3-triazole. 2.92 g of 2-(tetrahydrofuran-3-methyl)-4-bromo-5-chloro-2H-1,2,3-triazole oily matter was obtained, the yield was 88%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.34 (d, J=7.6, 2H), 3.93-3.88 (m, 1H), 3.82-3.73 (m, 2H), 3.62 (dd, J=5.2, 9.2 Hz, 1H), 2.94-2.86 (m, 1H), 2.10-2.01 (m, 1H), 1.73-1.68 (m, 1H); 13 C NMR (CDCl 3 , 400 MHz): δ 137.2, 121.0, 70.6, 67.5, 58.7, 39.3, 29.6.
EXAMPLE 8
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 4.0 g (12.45 mmol) of 2-cyclohexyl methyl-4,5-dibromo-2H-1,2,3-triazole. 2.95 g of 2-cyclohexyl methyl-4-bromo-5-chloro-2H-1,2,3-triazole oily matter was obtained, the yield was 85%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.17 (d, J=7.6 Hz, 2H), 2.02-1.94 (m, 1H), 1.75-1.58 (m, 5H), 1.28-1.13 (m, 3H), 1.04-0.94 (m, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 136.7, 120.4, 62.6, 38.3, 30.3, 26.1, 25.5.
EXAMPLE 9
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 3.87 g (12.45 mmol) of 2-(4-tetrahydropyran)-4,5-dibromo-2H-1,2,3-triazole. 2.95 g of 2-(4-tetrahydropyran)-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 89%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.62-4.54 (m, 1H), 4.08 (dt, J=3.6, 11.6 Hz, 2H), 3.53 (dt, J=2.8, 11.6 Hz, 2H), 2.25-2.15 (m, 4H); 13 C NMR (CDCl 3 , 400 MHz): δ 136.9, 120.7, 66.2, 62.5, 32.0.
EXAMPLE 10
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 3.32 g (12.45 mmol) of 2-allyl-4,5-dibromo-2H-1,2,3-triazole. 2.49 g of 2-allyl-4-bromo-5-chloro-2H-1,2,3-triazole oily matter was obtained, the yield was 90%. 1 H NMR (CDCl 3 , 500 MHz): δ 6.07-5.99 (m, 1H), 5.35 (dd, J=0.5, 4.0 Hz, 1H), 5.25 (dd, J=0.5, 11.0 Hz, 1H), 4.95 (dt, J=1.0, 7.5 Hz, 2H); 13 C NMR (CDCl 3 , 500 MHz): δ 137.3, 130.3, 121.1, 120.8, 58.8.
EXAMPLE 11
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 4.12 g (12.45 mmol) of 2-phenethyl-4,5-dibromo-2H-1,2,3-triazole. 3.10 g of 2-phenethyl-4-bromo-5-chloro-2H-1,2,3-triazole oily matter was obtained, the yield was 87%. 1 H NMR (CDCl 3 , 500 MHz): δ 7.30 (t, J=2.5 Hz, 2H), 7.26-7.23 (m, 1H), 7.16 (d, J=7.0 Hz, 2H), 4.56 (t, J=7.5 Hz, 2H), 3.21 (t, J=7.5 Hz, 2H); 13 C NMR (CDCl 3 , 500 MHz): δ 137.0, 136.6, 128.8, 128.7, 127.1, 120.7, 57.6, 35.8.
EXAMPLE 12
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 4.17 g (12.45 mmol) of 2-p-fluorobenzyl-4,5-dibromo-2H-1,2,3-triazole. 2.89 g of 2-p-fluorobenzyl-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 80%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.35 (dd, J=8.4, 8.8 Hz, 2H), 7.05 (t, J=8.8 Hz, 2H), 5.44 (s, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 163.0 (d, J=247.0 Hz), 137.6, 130.4 (d, J=9.0 Hz), 129.6 (d, J=3.0 Hz), 121.5, 116.0 (d, J=22.0 Hz), 59.4.
EXAMPLE 13
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 4.17 g (12.45 mmol) of 2-m-fluorobenzyl-4,5-dibromo-2H-1,2,3-triazole. 2.97 g of 2-m-fluorobenzyl-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 82%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.36-7.31 (m, 1H), 7.12 (d, J=7.6 Hz, 1H), 7.06-7.03 (m, 2H), 5.47 (s, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 162.8 (d, J=246.0 Hz), 137.8, 136.0 (d, J=7.3 Hz), 130.6 (d, J=8.2 Hz), 124.0 (d, J=3.1 Hz), 121.6, 116.0 (d, J=20.9 Hz), 115.4 (d, J=23.0 Hz), 59.5 (d, J=20.0 Hz).
EXAMPLE 14
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 4.38 g (12.45 mmol) of 2-m-chlorobenzyl-4,5-dibromo-2H-1,2,3-triazole. 3.25 g of 2-m-chlorobenzyl-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 85%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.34-7.30 (m, 3H), 7.22 (dt, J=1.6, 7.2 Hz, 1H), 5.45 (s, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 137.8, 135.6, 134.9, 130.3, 129.2, 128.5, 126.5, 121.7, 59.4.
EXAMPLE 15
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 4.93 g (12.45 mmol) of 2-p-bromobenzyl-4,5-dibromo-2H-1,2,3-triazole. 3.67 g of 2-p-bromobenzyl-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 84%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.50 (ABq, J=8.4 Hz, 2H), 7.23 (ABq, J=8.4 Hz, 2H), 5.43 (s, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 137.7, 132.7, 132.2, 130.1, 123.2, 121.6, 59.5.
EXAMPLE 16
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 4.30 g (12.45 mmol) of 2-(3,5-dimethylbenzyl)-4,5-dibromo-2H-1,2,3-triazole. 3.29 g of 2-(3,5-dimethylbenzyl)-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 88%. 1 H NMR (CDCl 3 , 400 MHz): δ 6.98 (s, 1H), 6.97 (s, 2H), 5.40 (s, 2H), 2.31 (s, 6H); 13 C NMR (CDCl 3 , 400 MHz): δ 138.7, 137.4, 133.6, 130.6, 126.2, 121.2, 60.3, 21.4.
EXAMPLE 17
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 3.95 g (12.45 mmol) of 2-benzyl-4,5-dibromo-2H-1,2,3-triazole. 3.12 g of 2-benzyl-4-bromo-5-chloro-2H-1,2,3-triazole oily matter was obtained, the yield was 92%. 1 H NMR (CDCl 3 , 500 MHz): δ 7.39-7.33 (m, 5H), 5.48 (s, 2H); 13 C NMR (CDCl 3 , 500 MHz): δ 137.5, 133.9, 129.0, 128.9, 128.4, 121.3, 60.3.
EXAMPLE 18
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 4.80 g (12.45 mmol) of 2-p-trifluoromethylbenzyl-4,5-dibromo-2H-1,2,3-triazole. 3.18 g of 2-p-trifluoromethylbenzyl-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 75%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.63 (ABq, J=8.0 Hz, 2H), 7.46 (ABq, J=8.0 Hz, 2H), 5.54 (s, 2H).
EXAMPLE 19
The operation method was the same as that of Example 1, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 4.32 g (12.45 mmol) of 2-p-methoxybenzyl-4,5-dibromo-2H-1,2,3-triazole. 3.28 g of 2-p-methoxybenzyl-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 87%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.31 (ABq, J=8.8 Hz, 2H), 6.89 (ABq, J=8.8 Hz, 2H), 5.41 (s, 2H), 3.80 (s, 3H); 13 C NMR (CDCl 3 , 400 MHz): δ 160.1, 137.3, 130.0, 125.9, 121.1, 114.3, 59.8, 55.3.
EXAMPLE 20
The operation method was the same as that of Example 1, chlorine was replaced with 1.66 g (12.45 mmol) of N-chlorosuccinimide. 1.47 g of 2-methyl-4-bromo-5-chloro-2H-1,2,3-triazole solid was obtained, the yield was 60%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.15 (s, 3H); 13 C NMR (CDCl 3 , 400 MHz): δ 137.0, 120.8, 43.1.
EXAMPLE 21
1.20 g (5.0 mmol) of 2-methyl-4,5-dibromo-2H-1,2,3-triazole was dissolved in 10 ml of tetrahydrofuran, cooled to −20˜0° C., 2.74 ml (5.18 mmol) of 2.0M isopropylmagnesium tetrahydrofuran solution was added dropwise slowly over 30 minutes. Once the dropwise addition was completed, stirring was continued for 30˜60 minutes. 1.26 g (5.0 mmol) of solid iodine was added, continued to react for 30 minutes. Reaction liquid was added by 20 ml of saturated ammonium chloride aqueous solution, extracted using 30 ml of ethyl acetate, dried by anhydrous sodium sulfate, and was concentrated to dry under reduced pressure. The residual solid was added by 10 ml of isopropanol/water (5/1), heated to reflux for 1 hour, cooled to 0˜10° C., continued to be stirred for 1 hour, filtered, vacuum dried under a temperature <40° C. 1.16 g of 2-methyl-4-bromo-5-iodo-2H-1,2,3-triazole solid was obtained, and the yield was 81%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.20 (s, 3H); 13 C NMR (CDCl 3 , 400 MHz): δ 130.4, 94.6, 43.0.
EXAMPLE 22
The operation method was the same as that of Example 21, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 1.17 g (5 mmol) of 2-ethyl-4,5-dibromo-2H-1,2,3-triazole. 1.28 g of 2-ethyl-4-bromo-5-iodo-2H-1,2,3-triazole solid was obtained, the yield was 85%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.46 (q, J=7.2 Hz, 2H), 1.55 (t, J=7.2 Hz, 3H); 13 C NMR (CDCl 3 , 400 MHz): δ 130.2, 94.3, 51.6, 14.7.
EXAMPLE 23
The operation method was the same as that of Example 21, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 1.48 g (5 mmol) of 2-cyclobutylmethyl-4,5-dibromo-2H-1,2,3-triazole. 1.33 g of 2-cyclobutylmethyl-4-bromo-5-iodo-2H-1,2,3-triazole solid was obtained, the yield was 78%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.41 (d, J=7.6 Hz, 2H), 2.94-2.86 (m, 1H), 2.11-2.04 (m, 2H), 1.96-1.78 (m, 4H); 13 C NMR (CDCl 3 , 400 MHz): δ 130.2, 94.3, 61.2, 35.1, 25.6, 18.2.
EXAMPLE 24
The operation method was the same as that of Example 21, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 1.47 g (5 mmol) of 2-cyclopentyl-4,5-dibromo-2H-1,2,3-triazole. 1.37 g of 2-cyclopentyl-4-bromo-5-iodo-2H-1,2,3-triazole solid was obtained, the yield was 80%. 1 H NMR (CDCl 3 , 400 MHz): δ 5.00-4.93 (m, 1H), 2.18-2.12 (m, 4H), 1.93-1.82 (m, 2H), 1.73-1.67 (m, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 129.8, 93.9, 67.9, 32.8, 24.3.
EXAMPLE 25
The operation method was the same as that of Example 21, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 1.55 g (5 mmol) of 2-(4-tetrahydropyran)-4,5-dibromo-2H-1,2,3-triazole. 1.47 g of 2-(4-tetrahydropyran)-4-bromo-5-iodo-2H-1,2,3-triazole solid was obtained, the yield was 82%. 1 H NMR (CDCl 3 , 400 MHz): δ 4.65-4.51 (m, 1H), 4.07 (dt, J=4.0, 11.6 Hz, 2H), 3.52 (dt, J=2.0, 11.6 Hz, 2H), 2.25-2.11 (m, 4H); 13 C NMR (CDCl 3 , 400 MHz): δ 130.3, 94.6, 66.2, 62.5, 32.2.
EXAMPLE 26
The operation method was the same as that of Example 21, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 1.58 g (5 mmol) of 2-benzyl-4,5-dibromo-2H-1,2,3-triazole. 1.45 g of 2-benzyl-4-bromo-5-iodo-2H-1,2,3-triazole solid was obtained, the yield was 80%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.37-7.33 (m, 5H), 5.55 (s, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 134.0, 131.0, 129.0, 128.9, 128.4, 95.2, 60.1.
EXAMPLE 27
The operation method was the same as that of Example 21, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 1.75 g (5 mmol) of 2-p-chlorobenzyl-4,5-dibromo-2H-1,2,3-triazole. 1.59 g of 2-p-chlorobenzyl-4-bromo-5-iodo-2H-1,2,3-triazole solid was obtained, the yield was 80%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.33 (ABq, J=3.6 Hz, 2H), 7.30 (ABq, J=3.6 Hz, 2H), 5.51 (s, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 135.0, 132.4, 131.2, 129.8, 129.2, 95.5, 59.4.
EXAMPLE 28
The operation method was the same as that of Example 21, 2-methyl-4,5-dibromo-2H-1,2,3-triazole was replaced with 1.98 g (5 mmol) of 2-p-bromobenzyl-4,5-dibromo-2H-1,2,3-triazole. 1.86 g of 2-p-bromobenzyl-4-bromo-5-iodo-2H-1,2,3-triazole solid was obtained, the yield was 84%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.49 (ABq, J=8.4 Hz, 2H), 7.22 (ABq, J=8.4 Hz, 2H), 5.49 (s, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 132.9, 132.2, 131.2, 130.1, 123.2, 95.5, 59.4.
EXAMPLE 29
1.96 g (10 mmol) of 2-methyl-4-bromo-5-chloro-1,2,3-triazole was dissolved in 20 ml of tetrahydrofuran, cooled to −20˜−10° C., 9.0 ml (11.71 mmol) of 2.0M isopropylmagnesium chloride lithium chloride composite tetrahydrofuran solution was added dropwise slowly over 30 minutes. Once the dropwise addition was completed, stirring was continued for 30˜60 minutes. Carbon dioxide was inleted slowly for about 1 minute until reaction liquid was no longer heating up. Reaction liquid was added by 30 ml of 0.5 mole/liter hydrochloric acid solution, extracted using 30 ml of ethyl acetate, dried by anhydrous sodium sulfate, and was concentrated to dry under reduced pressure. The residual solid was added by 20 ml of methyl tertiary butyl ether/n-hexane ( 1/10), heated to reflux for 1 hour, cooled to 0˜10° C., continued to be stirred for 1 hour, filtered, vacuum dried under a temperature <40° C. 1.4 g of 2-methyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, and the yield was 85%. 1 H NMR (DMSO-d 6 , 400 MHz): δ 4.21 (s, 3H); 13 C NMR (DMSO-d 6 , 400 MHz): δ 160.1, 137.1, 135.2, 42.9.
EXAMPLE 30
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.10 g (10 mmol) of 2-ethyl-4-chloro-5-bromo-2H-1,2,3-triazole. 1.54 g of 2-ethyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 88%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 4.53 (q, J=7.2 Hz, 2H), 1.56 (t, J=7.2 Hz, 3H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 160.5, 138.8, 135.9, 52.3, 14.6.
EXAMPLE 31
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.24 g (10 mmol) of 2-n-propyl-4-chloro-5-bromo-2H-1,2,3-triazole. 1.61 g of 2-n-propyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 85%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 4.53 (q, J=7.2 Hz, 2H), 1.56 (t, J=7.2 Hz, 3H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 160.5, 138.8, 135.9, 52.3, 14.6.
EXAMPLE 32
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.51 g (10 mmol) of 2-cyclopentyl-4-chloro-5-bromo-2H-1,2,3-triazole. 1.94 g of 2-cyclopentyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 90%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 5.11-5.07 (m, 1H), 2.27-2.14 (m, 4H), 1.91-1.86 (m, 2H), 1.79-1.72 (m, 2H); 13 C NMR (CD 3 COCD 3 , 400 MHz) δ 160.5, 138.7, 135.6, 68.6, 33.2, 24.9.
EXAMPLE 33
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.67 g (10 mmol) of 2-(tetrahydrofuran-3-methyl)-4-chloro-5-bromo-2H-1,2,3-triazole. 1.92 g of 2-(tetrahydrofuran-3-methyl)-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 83%. 1 H NMR (CD 3 COCD 3 , 500 MHz): δ 4.51 (d, J=7.5, 2H), 3.85 (m, 1H), 3.78 (dd, J=7.0, 9.0 Hz, 1H), 3.69 (q, J=7.0 Hz, 1H), 3.60 (dd, J=5.0, 9.0 Hz, 1H), 2.95-2.88 (m, 1H), 2.11-2.04 (m, 1H), 1.77-1.68 (m, 1H); 13 C NMR (CD 3 COCD 3 , 500 MHz) δ 160.4, 139.1, 136.1, 71.0, 67.8, 59.3, 40.1, 30.2.
EXAMPLE 34
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.78 g (10 mmol) of 2-cyclohexyl methyl-4-chloro-5-bromo-2H-1,2,3-triazole. 2.02 g of 2-cyclohexyl methyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 83%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 4.32 (d, J=7.2 Hz, 2H), 2.07-2.00 (m, 1H), 1.75-1.61 (m, 5H), 1.32-1.18 (m, 3H), 1.12-1.02 (m, 2H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 160.5, 138.9, 135.9, 62.9, 39.1, 30.8, 26.8, 26.2.
EXAMPLE 35
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.67 g (10 mmol) of 2-(4-tetrahydropyran)-4-chloro-5-bromo-2H-1,2,3-triazole. 2.06 g of 2-(4-tetrahydropyran)-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 89%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 4.86-4.79 (m, 1H), 4.05 (dt, J=3.6, 11.6 Hz, 2H), 3.59 (dt, J=2.4, 11.6 Hz, 2H), 2.23-2.10 (m, 4H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 160.5, 138.9, 135.9, 66.5, 63.3, 33.0.
EXAMPLE 36
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.36 g (10 mmol) of 2-cyclopropyl methyl-4-chloro-5-bromo-2H-1,2,3-triazole. 1.81 g of 2-cyclopropyl methyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 90%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 4.35 (d, J=7.6 Hz, 2H), 1.47-1.36 (m, 1H), 0.66-0.61 (m, 2H), 0.51-0.47 (m, 2H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 160.5, 138.9, 136.0, 61.3, 11.4, 4.2.
EXAMPLE 37
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.50 g (10 mmol) of 2-cyclobutyl methyl-4-chloro-5-bromo-2H-1,2,3-triazole. 1.77 g of 2-cyclobutyl methyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 82%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 4.50 (d, J=7.2 Hz, 2H), 2.99-2.91 (m, 1H), 2.11-2.05 (m, 2H), 1.95-1.89 (m, 4H); 13 C NMR (CD 3 COCD 3 , 400 MHz) δ 160.5, 138.9, 136.0, 61.6, 35.8, 26.1, 18.6.
EXAMPLE 38
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.22 g (10 mmol) of 2-allyl-4-chloro-5-bromo-2H-1,2,3-triazole. 1.18 g of 2-allyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 63%. 1 H NMR (CDCl 3 , 400 MHz): δ 6.18-6.08 (m, 1H), 5.37 (dd, J=1.2, 6.4 Hz, 1H), 5.34 (s, 1H), 5.12 (dt, J=1.2, 6.4 Hz, 2H); 13 C NMR (CDCl 3 , 400 MHz) δ 160.4, 139.2, 136.3, 131.9, 120.4, 59.3.
EXAMPLE 39
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.87 g (10 mmol) of 2-phenethyl-4-chloro-5-bromo-2H-1,2,3-triazole. 2.16 g of 2-phenethyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 86%. 1 H NMR (CDCl 3 , 400 MHz): δ 7.31-7.20 (m, 5H), 4.73 (t, J=7.2 Hz, 2H), 3.32 (t, J=7.2 Hz, 2H); 13 C NMR (CDCl 3 , 400 MHz): δ 160.4, 138.9, 138.2, 136.0, 129.6, 129.4, 127.7, 58.2, 35.9.
EXAMPLE 40
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.90 g (10 mmol) of 2-p-fluorobenzyl-4-chloro-5-bromo-2H-1,2,3-triazole. 1.97 g of 2-p-fluorobenzyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 77%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 7.51 (dd, J=5.6, 8.4 Hz, 2H), 7.18 (dd, J=8.4, 8.8 Hz, 2H), 5.69 (s, 2H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 163.8 (d, J=244.0 Hz), 160.3, 139.4, 136.6, 131.7 (d, J=9.0 Hz), 131.5 (d, J=3.0 Hz), 116.5 (d, J=21.0 Hz), 59.8.
EXAMPLE 41
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.90 g (10 mmol) of 2-m-fluorobenzyl-4-chloro-5-bromo-2H-1,2,3-triazole. 2.07 g of 2-m-fluorobenzyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 81%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 7.46-7.42 (m, 1H), 7.26 (d, J=7.6 Hz, 1H), 7.23 (dd, J=2.0, 9.6 Hz, 1H), 7.15 (dt, J=2.0, 8.8 Hz, 1H), 5.76 (s, 2H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 163.6 (d, J=244.0 Hz), 160.4, 139.6, 137.8 (d, J=7.0 Hz), 136.7, 131.7 (d, J=8.0 Hz), 125.2 (d, J=3.0 Hz), 116.4 (d, J=21.0 Hz), 116.2 (d, J=23.0 Hz), 59.9 (d, J=2.0 Hz).
EXAMPLE 42
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 2.72 g (10 mmol) of 2-benzyl-4-chloro-5-bromo-2H-1,2,3-triazole. 1.90 g of 2-benzyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 80%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 7.44-7.35 (m, 5H), 5.69 (s, 2H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 160.4, 139.4, 136.5, 135.4, 129.7, 129.5, 129.3, 60.6.
EXAMPLE 43
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 3.51 g (10 mmol) of 2-p-bromobenzyl-4-chloro-5-bromo-2H-1,2,3-triazole. 2.85 g of 2-p-bromobenzyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 90%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 7.60 (ABq, J=8.4 Hz, 2H), 7.40 (ABq, J=8.4 Hz, 2H), 5.70 (s, 2H); 13 C NMR (CD 3 COCD 3 , 400 MHz) δ 160.3, 139.5, 136.7, 134.7, 132.8, 131.5, 123.2, 59.8.
EXAMPLE 44
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 3.00 g (10 mmol) of 2-(3,5-dimethylbenzyl)-4-chloro-5-bromo-2H-1,2,3-triazole. 2.28 g of 2-(3,5-dimethylbenzyl)-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 86%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 7.02 (s, 2H), 7.00 (s, 1H), 5.58 (s, 2H), 2.28 (s, 3H), 2.27 (s, 3H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 160.4, 139.3, 139.2, 136.4, 135.2, 131.0, 127.0, 60.7, 21.2.
EXAMPLE 45
The operation method was the same as that of Example 29, 2-methyl-4-chloro-5-bromo-2H-1,2,3-triazole was replaced with 3.02 g (10 mmol) of 2-p-methoxybenzyl-4-chloro-5-bromo-2H-1,2,3-triazole. 2.52 g of 2-p-methoxybenzyl-5-chloro-2H-1,2,3-triazole-4-carboxylic acid solid was obtained, the yield was 94%. 1 H NMR (CD 3 COCD 3 , 400 MHz): δ 7.39 (ABq, J=8.8 Hz, 2H), 6.94 (ABq, J=8.8 Hz, 2H), 5.60 (s, 2H), 3.79 (s, 3H); 13 C NMR (CD 3 COCD 3 , 400 MHz): δ 161.1, 160.4, 139.3, 136.3, 131.0, 127.2, 115.0, 60.2, 55.6.
Although the present invention has been disclosed as above by better embodiments, it is not used to define the present invention. Slight modifications and improvements can be made by any person skilled in the art without departing from the spirit and scope of the present invention. Accordingly, the scope of protection of the present invention is defined by the follwing claims. | Disclosed is a 2-substituted-2H-1,2,3-triazole derivative, a compound as represented by formula I or II. Also disclosed is a preparation method of the compound as represented by formula I or II, in particular to a preparation method of 2-substituted-4-bromo-5-chloro-1H-1,2,3-triazole, 2-substituted-4-bromo-5-iodo-1H-1,2,3-triazole, and 2-substituted-5-chloro-1H-1,2,3-triazole-4-carboxylic acid. The preparation methods of the present invention are simple and feasible, and has high yield of the obtained compounds. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/968,825, filed Aug. 29, 2007, titled Furnace Filtration System For Molten Metal, the disclosure of which is expressly incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to the separation of solids from liquids and, more particularly, to filtering dross and other solid contaminants from molten metal.
BACKGROUND OF THE INVENTION
[0003] A typical molten metal facility includes a furnace with a pump for moving molten metal. During the processing of molten metals, such as aluminum, the molten metal is normally continuously circulated through the furnace by a centrifugal circulation pump to equalize the temperature of the molten bath. These pumps contain a rotating impeller that draws in and accelerates the molten metal creating a laminar-type flow within the furnace.
[0004] A well-known problem with such processes, however, is the accumulation of dross within the metal bath. Dross is a mass of solid impurities floating on and within a molten metal bath. It usually appears within molten metals or alloys having a relatively low melting point, such as tin, lead, zinc or aluminum, or by oxidation of these metals. Other impurities, such as pieces of the furnace's refractory material may also be found within such a molten metal bath.
[0005] The dross can range in size from small particles to relatively large pieces or chunks. The smaller dross material, while undesirable, does not normally pose a threat to the operation of the furnace and its circulation pump(s). However, the larger pieces of dross can, and often do, get pulled into the pump and cause the pump to become jammed, causing catastrophic failure to occur.
[0006] As a result of this problem, furnace operators frequently must run their circulation pumps at a relatively low speed, such as approximately 250-300 rpm. This slower speed, while reducing the damage to the pump components if a larger piece of dross becomes lodged therein, results in the undesirable condition of the pump motor being operated at much less than peak efficiency. That is, through the use of a frequency converter, a motor can produce the necessary torque at these lower speeds, but resulting in only using 10-15% of the available motor horsepower.
[0007] Another common solution to the pump-damaging large dross pieces within a furnace is to install larger and larger pumps having impellers that will receive and transfer all but the largest contaminants. These pumps, however, are expensive and they waste energy by continually pushing the dross through the system. Furthermore, as the dross is circulated through the furnace along with the molten metal, the dross pieces tend to accumulate together or conglomerate to create larger and larger pieces. Eventually, these growing pieces of dross may reach a size that will jam within even a very large impeller.
[0008] Currently, there are filters that are placed at the furnace discharge. These filters prevent dross from exiting the furnace—not from entering the pumps. Additionally, they do not provide for a user to collect the filtered contaminants from the system. Instead, the contaminants are left free to settle throughout the furnace.
[0009] In view of the current inefficient use of molten metal pumps, there is a need for a system for filtering the larger dross pieces in the furnace from entering a molten metal pump, thereby allowing the pump to operate at higher speeds and increasing efficiency within the system. Additionally, there is a need for such a filtering system that enables a user to quickly clean out the accumulated filtered contaminants from the furnace.
SUMMARY OF THE INVENTION
[0010] The present invention provides a filtration well adapted to filter solid contaminants from a bath of molten metal that are too large to pass through the impeller openings of a centrifugal impeller pump located within a pump well. The filtration well includes at least two walls that cooperate to define an enclosure having an upstream section and a downstream section, wherein the upstream section includes an inlet arch and the downstream section includes an outlet arch. The outlet arch is in direct fluid communication with the pump well. A filter covers the outlet arch and includes bore means which prevent solid contaminants that are sized larger than the impeller openings from passing therethrough, but allow solid contaminants that are smaller than the impeller openings to flow through.
[0011] The present invention also provides a filtration system for a molten metal bath having a pump well containing a centrifugal impeller pump. The impeller pump having impeller openings which receive and pump molten metal and any solid contaminants within the molten metal that are smaller than the impeller openings. The filtration system includes an upstream filtration well that is fluidly coupled upstream to the pump well. The filtration well including an inlet wall having an enlarged inlet opening and a spaced outlet wall having an enlarged outlet opening, wherein the filtration well is in fluid communication with the pump well through the outlet opening. The filtration system also includes a furnace filter having a body that is sized to cover the outlet opening. The body includes a plurality of filter bores or openings, each of the filter bores or openings being smaller than the impeller openings, whereby contaminants larger than the filter bores are retained within the upstream filtration well and molten metal and contaminants smaller than the filter bores pass through the furnace filter and into the pump well. The filtration system also includes means for removably retaining the furnace filter over the outlet opening.
[0012] The present invention further provides a method of increasing the operating speed of a centrifugal pump within a bath of molten metal. This method includes the steps of: forming a filtration well directly upstream of the pump well, wherein the filtration well includes a pair of spaced walls, wherein one of the walls includes an inlet arch and the other wall includes an outlet arch, the outlet arch being in fluid communication with said pump well; providing a furnace filter; and preventing all solid contaminants that are larger than the pump's impeller openings from entering the pump well by covering the outlet arch with the furnace filter.
[0013] The present invention is a molten metal filtering system that prevents over-sized contaminants from being pulled into a molten metal recirculation pump. This system includes a filter well that is disposed upstream of the furnace's pump well. The filter well is generally defined by two pairs of spaced opposed walls. These walls act as an inlet and outlet to the filter well as each has a through opening or arch. The inlet wall is in fluid communication with the furnace, while the outlet wall is in fluid communication with the pump well.
[0014] In the preferred embodiment, the outlet wall opening is covered by a filter plate. The outlet wall includes a generally flat filter plate having a plurality of through filter bores that allow molten metal to pass through the filter and into the pump well. Each filter bore is sized to prevent any solid contaminants that are larger than the pump impeller's openings to pass through the filter and into the pump well.
[0015] By filtering all of the potentially pump-damaging pieces of dross from entering the pump well, the pumps located within the pump well may be freely operated at a much higher speed, which dramatically increases the flow rate of the molten metal bath within the furnace. Running the pump at this more efficient speed will typically require the output from the pump to be diffused to optimize the penetration into the charge well, additionally any pump-safe sized solid contaminants are also preferably removed from the furnace.
[0016] A centrifugal pump's efficiency increases with rotational speed along with the flow and pressure. Increased flow and pressure increases a furnace's efficiency by increasing the melting rate; decreasing the energy lost by reducing the metal temperature stratification; and reducing the contaminants, which increases the quality of the metal produced thereby reducing the amount of nitrogen and chlorine needed to clean the metal.
[0017] It is an advantage of the present invention to provide a filtration system that will prevent large pieces of dross from damaging a furnace's molten metal pump, thereby allowing the pump to run at a higher, more efficient speed.
[0018] It is another advantage of the present invention that the filters can be readily removed and replaced from the filtration system to reduce furnace downtime.
[0019] It is still another advantage of the present invention that the filtration system provides a dross filtration well that collects and retains the filtered dross in an easily accessible location.
[0020] These and other objects, features and advantages of the present invention will become apparent from the following description when viewed in accordance with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The description refers to the accompanying drawings in which like reference characters refer to like parts throughout the several views, and in which:
[0022] FIG. 1 is a cut-away perspective view of the preferred molten metal filtration well;
[0023] FIG. 2 is a top view of the upstream filtration well;
[0024] FIG. 3 is a front view of the pump well inlet filter plate;
[0025] FIG. 4 is a partial side view of the pump well inlet filter covering the pump well inlet arch;
[0026] FIG. 5 is a top sectional view of a high flow centrifugal impeller pump;
[0027] FIG. 6 is a partial top sectional view of the through bore shape for the filtration system's filter;
[0028] FIG. 7 is a cut-away perspective view of the molten metal filtration well and an alternate configuration of the filter;
[0029] FIG. 8 is a perspective view of the alternate configuration of the filter shown in FIG. 7 ;
[0030] FIG. 9 is a top view of the upstream filtration well shown in FIG. 7 with an alternate configuration filter installed;
[0031] FIG. 10 is a partial top view of an alternate filter retention bracket;
[0032] FIG. 11 is a sectional view through line A-A in FIG. 10 ;
[0033] FIG. 12 is a partial side sectional view of an alternate filter having a angled lower filter bores;
[0034] FIG. 13 is a partially exploded perspective view of an alternate filter having inert graphite filter tubes;
[0035] FIG. 14 is an assembled perspective view of the alternate filter shown in FIG. 13 ;
[0036] FIG. 15 is a perspective view of an another alternate configuration of the filter plate;
[0037] FIG. 16 is a front view of still another alternate configuration of the filter plate, including inert graphite filter grates;
[0038] FIG. 17 is sectional view of an inert gas saturated, insulated, graphite filter tube;
[0039] FIG. 18 is a perspective view of yet another alternate configuration of the filter;
[0040] FIG. 19 is a cut-away perspective view of a molten metal recirculation and transfer system, including an upstream filtration well and a downstream filter/transfer well;
[0041] FIG. 20 is a rear perspective view of the filter/gate valve used in the system illustrated in FIG. 19 ; and
[0042] FIG. 21 is another alternate embodiment illustrating a furnace filtration system formed by adapting a pre-existing furnace pump well.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0043] Referring now to FIGS. 1-4 , there is shown a preferred embodiment of the present invention. The present invention is molten metal filtration system 10 for a central melting or holding furnace, such as furnace 12 .
[0044] A conventional furnace 12 is generally shaped as a fluid retaining enclosure. This enclosure includes a heating area or hearth 13 , a pump well 14 that contains a molten metal circulation and/or a transfer pump 16 and a charge well 18 . A bath 20 of molten metal is contained within furnace 12 . A series of arches or gates fluidly connect the hearth, pump well and charge well allowing the molten metal to flow through the furnace. The bath 20 is heated in the hearth 13 , pulled into the pump well 14 by pump 16 and accelerated out from the pump and into the charge well 18 . Additional raw material sought to be melted is inserted into the furnace at charge well 18 .
[0045] Pump 16 is typically a high flow centrifugal impeller pump adapted to be immersed in molten metal. Pump 16 rotates an impeller 22 to draw in and expels the molten metal forming bath 20 . One example of such a pump is the type disclosed in my pending U.S. patent application Ser. No. 11/337,266 entitled HIGH FLOW/DUAL INDUCER/HIGH EFFICIENCY IMPELER FOR LIQUID APPLICATIONS INCLUDING MOLTEN METAL which is incorporated herein by reference, word for word and paragraph for paragraph. It should be appreciated that while pump 16 is being described as a centrifugal impeller-type of pump, it can be substantially any style pump suitable for use in a molten metal environment.
[0046] Bath 20 , while being primarily composed of the intended molten metal material, also contains solid contaminants or dross that flows throughout furnace 12 . Dross varies in size from particulate-type matter to large pieces 24 that can be at least partially pulled into pump 16 . These larger pieces of dross 24 oftentimes jam the rotating impeller 22 , resulting in damage to or clogging of the pump.
[0047] Filtration system 10 includes a filtration well 28 that is located within furnace 12 between hearth 13 and pump well 14 . Filtration well 28 is preferably a rectilinear enclosure defined by two pairs of opposed vertical walls 29 - 30 and 31 - 32 . Walls 29 - 32 are formed from the same material as the other furnace enclosure walls, typically a castable refractory cement. Two of the opposed walls 29 and 30 include passages or arches 33 , 34 .
[0048] Filtration well 28 is disposed relative to the rest of furnace 12 such that wall 29 separates well 28 from hearth 13 , while its interior region 35 is in fluid communication with hearth 13 via arch 33 . Wall 30 separates well 28 from pump well 14 , while interior region 35 is in fluid communication with pump well 14 via arch 34 . Walls 31 , 32 complete well 28 and separate the two arched walls 29 , 30 . As will be described in greater detail below, the distance walls 29 , 30 are spaced is sufficient to allow filtration well 28 to be readily cleaned out and to retain a significant amount of dross 24 .
[0049] Filtration well 28 includes at least one filter 36 . Filter 36 is preferably a rectangular flat sheet or plate body 37 formed from a ceramic material, such as silicon carbide or silicon nitride reaction-bonded silicon carbide. Filter 36 includes a plurality of substantially identical through bores 38 , which are arranged in an array and cooperate to form a rough screen or filter in body 37 . Importantly, each through bore 38 is sized slightly smaller than the impeller inlet opening 40 of the pump 16 . In this manner, the diameter of through bore 38 is wholly dependent upon the inlet opening 40 of the pump 16 located within the furnace 12 being filtered. In a typical furnace 12 , inlet opening 40 will be approximately 1½ inches in diameter, and the through bores 38 for such an inlet size would be approximately 1 to 1¼ inches in diameter. In one non-limiting embodiment, the area of the upstream openings 38 a is approximately 90% of the size of the impeller inlet opening 40 for the pump 16 located in pump well 14 .
[0050] It should be appreciated that by substantially covering the filter body 37 with through bores 38 , the flow of the molten metal 20 is not impeded, with negligible pressure drop across the arch-covering filter 36 .
[0051] In one embodiment, as shown in FIG. 6 , each through bore, denoted 38 ′, has a frusto-conical shape where the opening 38 a ′ at the upstream face 41 (i.e., the side that faces the bath 20 within region 35 ) of plate 36 tapers outwardly to the downstream opening 38 b ′. In this embodiment, opening 38 a ′ is substantially the same size as opening 38 a and will block any solid contaminants larger than impeller inlet opening 40 . This tapered shape of the through bores 38 ′ reduces the possibility of the filter clogging and further reduces the difference in fluid pressure across filter 36 .
[0052] Filter plate 36 is disposed within filtration well 28 and is sized to cover the filtration well's outlet arch 34 (i.e., the pump well's inlet arch). It should be understood that the size and shape of filter plate 36 may vary as long as it substantially covers arch 34 . In an embodiment illustrated in FIG. 2 , wall 30 includes a filter slot 42 that is formed down through the top surface 30 a of wall 30 . Slot 42 is shaped complementary to and is sized to receive filter plate 36 . Slot 42 intersects and is substantially co-planar with arch 34 . Slot 42 extends longitudinally beyond arch 34 along wall 30 forming a pair of vertical channels 43 that abuttingly receive the opposite edges of filter plate 36 and cooperate to retain the filter plate within filtration well 28 . In one embodiment, the upstream face of wall 30 includes an opening 44 approximately the same width as arch 34 and extends up through the top surface 30 a of wall 30 . Opening 44 is aligned with and intersects slot 42 and presents the substantially the entire upstream face 41 of filter 36 to the metal bath in filtration well 28 .
[0053] As best shown in FIG. 4 , filter 36 preferably projects from its retention means above the upper surface 30 a of wall 30 , such that the top edge 36 a may be grasped to remove filter 36 from furnace filtration system 10 . Means for withdrawing the filter, such as apertures 39 formed through the filter 36 proximate to its top edge 36 a , are preferably provided to facilitate removal of filter 36 from the furnace 12 .
[0054] In the embodiment illustrated in FIG. 1 , arches 33 , 34 are formed in the walls 29 , 30 . Each arch 33 , 34 preferably is an opening extending up the wall from the floor 45 of the filtration well 28 . It should be understood that the location, shape and/or size of these arches may vary and that the filters and filter retaining means, such as slot 42 , may vary accordingly.
[0055] Referring now to FIGS. 7-9 , another embodiment of filtration well 28 replaces filter 36 with a box filter 46 . Filter 46 includes a rectangular box-like body that is formed from three upstream plate-like filter walls 47 , which are each similar in construction to filter 36 . Each filter wall 47 includes a plurality of identical through bores 38 , which are identical to the through bores formed in filter 36 . A fourth downstream filter wall 48 completes the box-like configuration to define an internal chamber 49 . It should be appreciated that the four-walled box configuration is exemplary in nature and that substantially any number of walls could be used to form box filter 46 .
[0056] In the preferred embodiment, downstream filter wall 48 is sized to be received in slot 42 , while upstream walls 47 project into filtration well 28 . That is, the outermost edges of downstream wall 48 extend beyond the upstream walls 47 forming a pair of outer mounting flanges 50 which are received within channels 43 .
[0057] Downstream filter wall 48 includes an array of identical through bores 51 . These bores 51 are smaller than bores 38 . The reduced size of bores 51 enables filter wall 48 to screen or filter even smaller particles of dross from the bath of molten metal, which may dynamically impact and damage the rotating impeller at higher rotating velocities.
[0058] Each through bore 38 in filter 46 is approximately 10% to 20% smaller than impeller inlet opening 40 to cause dross 24 that would otherwise damage the downstream pump 16 to be retained in filtration well 28 . In one embodiment, box filter 46 includes a closed bottom 52 that interconnects each of the walls 47 , 48 and allows the filter 46 to be periodically removed from well 28 to be emptied/cleaned and subsequently re-installed. In one embodiment, box filter 46 is approximately one-half to two-thirds the size of the filtration well 28 .
[0059] Box filter 46 thereby provides dual filtration by first screening out any pieces of dross that are larger than the impeller inlet opening 40 via upstream through bores 38 in walls 47 . These larger pieces of dross are retained within filtration well 28 . The finer filter bores 51 formed in downstream wall 48 further screens out even smaller pieces of dross to further protect the pump. That is, bores 51 block pieces of dross that will pass through the pump 16 , but may cause damage to the impeller 22 when the pump is run at higher velocities. These smaller pieces of dross are retained with retention chamber 49 . The pump 16 can then be accelerated to higher RPMs.
[0060] The above description illustrates how furnace filtration system 10 , through filters 36 , 46 and filtration well 28 prevents the larger non-pumpable pieces of dross 24 from entering pump well 14 , thereby preventing dross 24 from damaging or clogging the pump. In turn, system 10 enables a user to run pump 16 at a higher speed. By eliminating the chance of a dross 24 jamming pump 16 , the pump can be run at a speed that is at or near its peak efficiency, instead of a typical slower speed that may save the pump if such a contaminant was pulled into the pump (i.e., by running at a slower speed, the pump may only stop turning instead of resulting in a catastrophic/breakage event).
[0061] Further, by retaining all of the potentially pump-damaging dross pieces 24 within filtration well 28 , filtration system 10 can be readily cleaned by shoveling or scraping the floor 45 between the spaced upstream and downstream walls 29 , 30 .
[0062] In other embodiments, shown in FIGS. 10 and 11 , the filter slot 42 of filtration well 28 are replaced or supplemented by guide brackets 54 that are anchored to the top 30 a of wall 30 proximate to the arch 34 . These brackets 54 receive a filter and hold the filter plates 36 or filter box 46 over the arch opening.
[0063] In one embodiment, filters 36 , 46 and their corresponding retention means 42 , 54 are complementarily shaped so that the filters cannot be placed backwards.
[0064] In still another embodiment, illustrated in FIG. 12 , the bottom-most row or rows or through bores 38 ″ are angled upward from upstream face 41 to the downstream face of the filter 36 , 46 . This upward angle directs the flow of molten metal bath 20 slightly upward and causes the flowing bath 20 to exert a downward force on the filter 36 , 46 . This downward force resists any upheaval of filter 36 , 46 as bath 20 flows through the through bores, while ensuring that the upwardly directed flow through bores 38 ″ is dispersed by the remaining through bores 38 to prevent any ripples on the surface of bath 20 , which could result in increased oxidation of the molten metal.
[0065] Referring now to FIGS. 13-18 and as disclosed in my previous U.S. Pat. No. 6,168,753 entitled INERT PUMP LEG ADAPTED FOR IMMERSION IN MOLTEN METAL which is incorporated herein by reference, word for word and paragraph for paragraph, injecting an inert gas into a graphite body having sufficient porosity to house the inert gas prevents the entry of either air or molten metal inside the flow tube—filtration plate. As best shown in FIG. 17 , a graphite tube 60 having an axial internal passage 61 is coated or covered with a layer 62 of suitable refractory cement material mixed with boron nitride paint.
[0066] A layer of nylon or fiberglass tape 63 covers the cement coated tube and is preferably wrapped around the tube in a helical pattern to ensure coverage of the tube. An outer layer 64 , also a mix of cement and boron nitride paint coats the tape layer 63 . The tape layer 63 is cemented by a combination of the refractory cement and boron nitride paint which constitutes inner and outer layers 62 and 64 .
[0067] As disclosed in my previous patent, an inert gas (e.g., nitrogen or argon) is pumped into passage 61 and the graphite is sufficiently porous to house the inert gas and prevent the entry of either air or molten metal to prevent the graphite from burning in the molten bath 20 .
[0068] It should be appreciated that multiple graphite tube 60 may be interconnected such that each internal conduit 61 is in fluid communication and where each insulating layer (e.g., layers 62 , 63 , and 64 ) substantially cover the molten metal-contacting surfaces, typically the outermost surfaces.
[0069] FIGS. 13 and 14 illustrate an alternate filtration plate, denoted 136 , having a generally rectangular frame 137 defining an interior cavity 138 . Frame 137 is sandwiched between two plates 140 , 142 , which are similar in construction to filter plate 36 , having a plurality of bores 143 formed therethrough. Like plate 36 , plates 140 , 142 are preferably formed from a molten aluminum heat resistant ceramic material, such as silicon carbide, silicon nitride reaction-bonded silicon carbide, or insulated-nitrogen saturated graphite to avoid burning at the metal line 20 A as discussed above and as disclosed in my previous U.S. Pat. No. 6,168,753. It should be appreciated that each bore 143 in the upstream plate 140 is axially aligned with a bore 143 in the downstream plate 142 .
[0070] A graphite flow tube 148 is mounted within cavity 138 between the plates 140 , 142 . Flow tube 148 is of a generally tubular construction and spans the gap between each aligned bore 143 of the opposing plates 140 , 142 , such that through bore 146 formed in each flow tube traverse the thickness of filtration plate 136 . In the preferred embodiment each flow tube fits within bores 143 and is cemented to plates 140 , 142 using refractory cement. A complementarily shaped ceramic or graphite frame 137 is disposed within and cemented to each plate 140 , 142 to prevent the molten aluminum from coming inside the filter body pressurized with nitrogen. Filtration plate 136 includes a fitting 148 having a gas-receiving passage 149 which is in fluid communication with cavity 138 for receiving an inert gas, such as nitrogen or argon, from a source 150 through conduit means 152 . Nitrogen is preferably injected into cavity 138 and is received by and saturates the graphite flow tubes 145 to prevent the tubes exposed above the molten metal line 20 A of furnace 12 from burning. In this embodiment, flow tubes 145 are shaped substantially the same as filter bores 38 .
[0071] Referring now to FIG. 15 , an alternate embodiment of a filtration plate, denoted 236 , is shown having a plurality of spaced parallel bars or tubes 237 that are coupled together at their opposite ends by a pair of support members 238 , 239 . Each bar or tube 237 is a generally cylindrical bar or tube formed from a heat resistant silicon carbide ceramic material or graphite which is properly insulated. With respect to the preferred graphite tube embodiment, the insulated graphite tubes are nitrogen saturated. The tubes 237 are spaced apart such that the gap 240 between adjacent tubes 237 is slightly smaller than the impeller inlet opening 22 of pump 16 . In this manner, plate 236 operates in substantially the same manner as filter plate 36 . The upper and lower support members 238 , 239 include a plurality of spaced apertures 241 which are shaped complementary to the tubes 237 . Tubes 237 are preferably fixed to support members 238 , 239 with refractory cement.
[0072] In this embodiment, both the upper and lower support bars 238 , 239 include internal passages 241 which are in fluid communication with the passages 61 of tubes 237 . The upper support bar 238 includes a fitting 148 which is in fluid communication with passages 61 and 241 for receiving an inert gas, such as nitrogen. The upper support bar 238 further includes retrieval apertures 39 , which enable the plate 236 to be readily retrieved. It should be appreciated that these apertures 39 are not connected with the nitrogen passage 241 . It should further be appreciated that plate 236 is sized to be readily received within retention means, such as slot 42 or guide brackets 54 located proximate to furnace arch 33 . While the embodiment illustrated in FIG. 15 depicts the filter bars 237 running vertically, it should be appreciated that bars 237 can be oriented at substantially any angle.
[0073] Referring now to FIG. 16 an alternate embodiment of the filtration plate 236 , denoted 336 is illustrated incorporating the inert graphite tubing described above. Filtration plate 336 includes a plurality of spaced graphite tubes 337 that span and interconnect a pair of graphite support members 338 , 339 . Tubes 337 and members 338 , 339 are insulated by applying a layer 62 of refractory cement mixed with boron nitride paint. Layer 62 bonds the layer 63 of fiberglass or nylon tape to the graphite bodies 337 - 339 . The tape layer 63 is coated with another layer 64 of suitable refractory cement and boron nitride paint mixture. Each graphite body 337 - 339 includes an internal conduit 342 (i.e., passages 61 ) which are fluidly interconnected and which receives an inert gas, such as nitrogen, through a fitting 148 mounted to one of the support members. Each tube 337 is spaced apart from the adjacent tube 337 a distance forming a gap 343 that is smaller than the impeller inlet opening 22 . Like filter plate 136 , filter plate 336 is sized to substantially cover inlet arch 33 , effective to prevent over-sized pieces of dross 24 within the furnace from entering the pump well 14 .
[0074] Referring now to FIG. 18 yet another embodiment of a molten metal furnace filter, denoted 436 is shown. Filter 436 , like filter 46 is a box or basket filter having three upstream walls 447 and one downstream wall 448 which cooperate to define an inner cavity or space 449 . Each wall in filter 436 , unlike filter box 46 , is formed from an inert gas graphite filter body, similar to filter plate 336 .
[0075] That is, each of the three upstream walls 447 and the downstream wall 448 is formed from insulated graphite tubes, which are substantially the same as tubes 60 . The walls of filter 436 have an internal passage 450 (i.e., interconnected passages 61 ) that is injected with an inert gas, such as nitrogen. In the preferred embodiment, the internal passages within each wall are fluidly connected and receive nitrogen gas through a common fitting, such as fitting 148 . Like filter box 46 , the upstream walls are configured to prevent over-sized pieces of dross from entering space 449 , such that the plurality of parallel filter tubes 451 are spaced apart a distance that is slightly smaller than the impeller inlet opening 22 . The downstream wall 448 includes parallel filter tubes 452 which are spaced even closer together than tubes 450 to further filter even smaller pieces of dross from entering the pump well 14 .
[0076] In one embodiment, filter 436 includes a bottom plate 453 which includes a plurality of drain holes 454 , which aid in draining the molten metal from filter 436 when filter 436 is removed from furnace 12 .
[0077] Referring now to FIGS. 19 and 20 an alternate embodiment of filtration system 10 is shown where filtration well 28 is supplemented with a secondary transfer filtration unit 500 that is proximate to the pump well outlet arch 502 and charge well 18 . Filtration unit 500 includes a box filter/gate valve 504 that is similar in construction to filters 36 and 46 . This filter 504 , however, is configured to screen out or filter much smaller solid contaminants, which readily pass through pump 16 . In one embodiment, filter 504 includes a plurality of through bores 506 that are approximately 1/16th to ⅛th inches in size.
[0078] Filtration unit 500 is disposed downstream of the outlet 70 of pump 16 . As shown in FIG. 19 , unit 500 preferably includes a transfer well 507 that is defined by spaced dual walls 508 , 509 . Well 507 is located between pump well 14 and charge well 18 .
[0079] The upstream wall 508 contains pump well outlet arch 502 and includes filter retention means, such as a filter guide slot 510 , which is similar in construction to slots 42 described above, such that filter 504 covers arch 502 . Similarly, downstream wall 509 contains charge well inlet arch 512 and includes filter retention means, such as filter guide slot 514 , which is substantially the same as and faces slot 510 . A transfer spout or outlet 516 is formed in the upper portion of the outer wall of well 507 .
[0080] As shown in FIG. 20 , filter 504 has a box-like configuration having three upstream filter walls 517 and a fourth downstream solid wall 518 . Filter walls 517 are similar to walls 47 of filter box 46 , with each walls 517 configured as a fine particle filter using a plurality of through bores 506 .
[0081] As the filter box 504 is lowered along slots 510 , 514 , solid wall 518 will close off the recirculation arch 512 (i.e., the arch passing into the charge well 18 ). Molten metal will begin filling transfer well 506 being filtered by a fine particle filter bores 506 in walls 517 . When the metal reaches the level of spout 516 , it will begin to transfer the finely filtered molten metal out of the furnace 12 . In this embodiment a bottom wall 520 interconnects the four walls 517 , 518
[0082] As the box filter/gate valve 504 is lifted, the pump 16 will resume recirculating the molten metal through the arches 502 and 512 in a normal manner with the bottom 520 of the filter box 504 as a top guide for the flow.
[0083] Referring now to FIG. 21 another embodiment of furnace filtration system 10 is illustrated, having a more compact filter well 28 which may be formed by adapting a pre-existing furnace 12 by reducing the size of pump well 14 by adding an additional wall 600 having another inlet arch 34 and filter retention means. In this embodiment, wall 600 is located between the original pump well return arch and the pump 16 . The original pump well return arch operates as the hearth return arch 33 discussed above.
[0084] From the foregoing description, one skilled in the art will readily recognize that the present invention is directed to a furnace molten metal filtration well, a system utilizing such a filtration well, and methods for using the same to improve pump speed and efficiency. While the present invention has been described with particular reference to various preferred embodiments, one skilled in the art will recognize from the foregoing discussion and accompanying drawing and claims that changes, modifications and variations can be made in the present invention without departing from the spirit and scope thereof. | A furnace filtration system for improving the speed and efficiency of a molten metal centrifugal impeller pump contained within a non-ferrous molten metal furnace. The system includes a filtration well located upstream of the pump well. The filtration well includes a filter having a plurality of through filter passages that are sized to prevent any solid contaminants that are larger than the pump's impeller openings from passing therethrough. By preventing any contaminants that cannot pass through the pump, the pump can be run at a higher speed. A furnaces efficiency increases with the centrifugal pump's efficiency increases with its centrifugal pump's speed along with the flow and pressure. Increased flow and pressure increases a furnace's efficiency by a) increasing the melting rate; b) decreasing the energy lost by reducing the metal temperature stratification; and c) reducing the contaminants increases the quality of the metal produced while reducing the amount of nitrogen and chlorine needed to clean the metal. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of the filing date under 35 USC 119(e) of the filing date of U.S. Provisional Application Ser. No. 60/674,785, filed Apr. 26, 2005.
BACKGROUND
This application relates generally to driving tools such as screwdrivers, nut drivers, bolt drivers, wrenches and the like wherein the amount of torque that the tool can apply to a given fastener is limited to a settable value. More specifically, this application relates to a torque locking mechanism usable in said tools that allows a fine range of torques for a given tool and prevents the inadvertent change of the torque setting once set.
Torque settable drivers as described above are well known in the art. This application relates to drivers that are designed for specific uses and thus a lockable torque value is desirable. The need for a lockable torque-limiting driver that can drive a given fastener at a desired torque value is useful in a variety of fields including sporting goods, electronics and computer assembly, and any other use wherein specific tolerances are required. However, it would be desirable if there was a tool that would allow for a fine range of torque setting such that a given tool could be effectively locked into a variety of specific torque settings. It would also be desirable for such a tool to be low-cost and suitable for mass production without sacrificing precision.
SUMMARY
This application discloses a settable torque-limiting driver that is economical to produce, of simple construction and capable of mass production, but also capable of being locked in a variety of precise torque settings.
In particular, this application discloses a lockable torque-limiting driver that includes gripping means, a body, a sleeve, a shaft carried by the body for rotation relative thereto and having a fastener-engaging tip at one end that projects from the body, torque-limiting means coupled to said shaft and housed within said body, torque-adjusting means within said body and coupled to said torque-limiting means for adjusting the torque-limiting means to a desired torque value, torque-locking means operably coupled with said torque-adjusting means and said body for preventing movement of said torque-determining means and locking the settable torque-limiting driver at the desired torque value.
In another embodiment, this application discloses a lockable torque-limiting driver that includes gripping means, a body, a sleeve, a shaft carried by the body for rotation relative thereto and having a fastener-engaging tip at one end that projects from the body, torque-limiting means coupled to said shaft and housed within said body, torque-adjusting means within said body and coupled to said torque-limiting means for adjusting the torque-limiting means to a desired torque value, torque-locking means operably coupled with said torque-adjusting means and said sleeve for preventing movement of said torque-determining means and locking the settable torque-limiting driver at the desired torque value.
In a further embodiment, this application discloses a method for locking a settable torque-limiting driver at a desired torque value by providing a torque-limiting mechanism coupled to a shaft and housed within a body, setting a torque-adjusting mechanism coupled to said torque-limiting mechanism, and engaging the torque-adjusting mechanism with a torque-locking mechanism.
In yet a further embodiment, this application discloses a golf club weight attachment system comprising: a golf club capable of being adjusted by securing screwably attachable weights in defined positions at a desired torque setting on said club; and, a lockable torque-limiting driver for securing said weights to said golf club at a defined torque setting wherein the driver comprises a body; a sleeve carried by said body; a shaft carried by said body for rotation relative thereto and having a weight-engaging tip at one end that projects from the body for screwably attaching said weights; torque-limiting means coupled to said shaft and housed within said body; torque-adjusting means within said body and coupled to said torque-limiting means for adjusting the torque-limiting means to the desired torque value; and, torque-locking means operably coupled with said torque-adjusting means and said body or said sleeve for preventing movement of said torque-determining means and locking the settable torque-limiting driver at the desired torque value such that the weights are attached to the golf club at the desired torque value.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings, when considered in connection with the following description, are presented for the purpose of facilitating an understanding of the subject matter sought to be protected.
FIG. 1A is a front elevational view of a lockable torque-limiting driver;
FIG. 1B is a sectional view of the driver taken generally along the line 1 B- 1 B in FIG. 1A showing a first embodiment of the locking mechanism;
FIG. 1C is an exploded view of the driver of FIG. 1A ;
FIG. 2A is a front elevational view of a lockable torque-limiting driver;
FIG. 2B is a sectional view of the driver taken generally along the line 2 B- 2 B in FIG. 2A showing a second embodiment of the locking mechanism;
FIG. 2C is an exploded view of the driver of FIG. 2A ;
FIG. 3A is a front elevational view of a lockable torque-limiting driver;
FIG. 3B is a sectional view of the driver taken generally along the line 3 B- 3 B in FIG. 3A showing a third embodiment of the locking mechanism;
FIG. 3C is an exploded view of the driver of FIG. 3A ;
FIG. 4 is a 90° side elevational view of the driver of FIG. 1A ;
FIG. 5 is a sectional view of the driver showing the first embodiment of the locking mechanism of FIG. 1B taken generally along the line 5 - 5 in FIG. 4 ;
FIG. 6 is a perspective view of the rotational cam of FIGS. 1C , 2 C, and 3 C;
FIG. 7 is a perspective view of the non-rotational cam of FIGS. 1C , 2 C, and 3 C;
FIG. 8 is perspective view of the sleeve of FIGS. 1C and 2C ;
FIG. 9A is a top plan view of the sleeve in FIG. 8 ;
FIG. 9B is a side elevational view of the sleeve in FIG. 8 ;
FIG. 9C is a 90° side elevational view of the sleeve in FIG. 9B ;
FIG. 9D is a sectional view of the sleeve taken generally along the line 9 D- 9 D in FIG. 9C ;
FIG. 10 is perspective view of the sleeve of FIG. 3C ;
FIG. 11A is a top plan view of the sleeve in FIG. 10 ;
FIG. 11B is a side elevational view of the sleeve in FIG. 10 ;
FIG. 11C is a 90° side elevational view of the sleeve in FIG. 11B ;
FIG. 11D is a sectional view of the sleeve taken generally along the line 11 D- 11 D in FIG. 11C ;
FIG. 12 is a top plan view of the generally circular member of the body of the driver of FIGS. 1C and 2C , isolated to show its details;
FIG. 13 is a perspective view of the adjustment plug of FIG. 1C ;
FIG. 13A is an additional perspective view of the adjustment plug of FIG. 1C ;
FIG. 13B is a top plan view of the adjustment plug of FIG. 1C ;
FIG. 13C is a side elevational view of the adjustment plug of FIG. 1C ;
FIG. 13D is a 90° side elevational view of the adjustment plug of FIG. 13C ;
FIG. 14 is a perspective view of the locking plate of FIG. 1C ;
FIG. 14A is an additional perspective view of the locking plate of FIG. 1C ;
FIG. 14B is a top plan view of the locking plate of FIG. 1C ;
FIG. 14C is a side elevational view of the locking plate of FIG. 1C ;
FIG. 14D is a 90° side elevational view of the locking plate of FIG. 14C ;
FIG. 15 is a perspective view showing the coupling of the adjustment plug and locking plate of the driver of FIG. 1B ;
FIG. 16 is a perspective view of the locking mechanism of the driver of FIG. 1B ;
FIG. 17 is a fragmentary sectional view along the line similar to the view in FIG. 5 showing the second embodiment of the locking mechanism of the driver of 2 B;
FIG. 18 is a perspective view showing the adjustment plug of the driver of FIGS. 3B and 3C ;
FIG. 18A is an additional perspective view of the adjustment plug of FIGS. 2C and 3C ;
FIG. 18B is a top plan view of the adjustment plug of FIGS. 2C and 3C ;
FIG. 18C is a side elevational view of the adjustment plug of FIGS. 2C and 3C ;
FIG. 18D is a 90° side elevational view of the adjustment plug of FIG. 18C ;
FIG. 19 is a perspective view showing the locking plate of the driver of FIG. 2C ;
FIG. 19A is an additional perspective view of the locking plate of FIG. 2C ;
FIG. 19B is a top plan view of the locking plate of FIG. 2C ;
FIG. 19C is a side elevational view of the locking plate of FIG. 2C ;
FIG. 19D is a 90° side elevational view of the locking plate of FIG. 19C ;
FIG. 19E is a bottom plan view of the locking plate of FIG. 2C ;
FIG. 20 is a perspective view showing the coupling of the adjustment plug and locking plate of the driver of FIG. 2B ;
FIG. 21 is a perspective view showing the locking mechanism of the driver of FIG. 2B ;
FIG. 22 is a fragmentary sectional view along the line similar to the view in FIG. 5 showing the third embodiment of the locking mechanism of the driver of 3 B;
FIG. 23A is an perspective view of the locking plate of FIG. 3C ;
FIG. 23B is a top plan view of the locking plate of FIG. 3C ;
FIG. 23C is a side elevational view of the locking plate of FIG. 3C ;
FIG. 23D is a 90° side elevational view of the locking plate of FIG. 23C ;
FIG. 23E is a bottom plan view of the locking plate of FIG. 3C ;
FIG. 24 is a perspective view showing the locking mechanism of the driver of FIG. 3B ;
FIG. 25 is an additional embodiment of the driver of FIG. 24 showing the locking mechanism of the driver of FIG. 3B used in a T-shaped driver;
FIG. 26 is a sectional view of the driver in FIG. 25 ; and,
FIG. 27 is a perspective view showing a golf club weight attachment system.
DETAILED DESCRIPTION
Referring to FIGS. 1A-3C , shown therein and generally designated by the reference character 10 is a lockable toque-limiting driver constructed in accordance with the following description. The driver 10 includes a body 12 having an elongated shaft 14 with a fastener-engaging portion 16 extending from one end thereof. At the other end, the driver 10 is provided with a cap member 18 .
As may be seen more clearly in FIGS. 1B and 5 , the body 12 is comprised of a generally circular upper member 13 and a hollow, generally cylindrical stem portion 15 with a tapered hexagonal shaped in transverse cross section end wall 17 terminating at its end with axial bore 19 formed therethrough. The inner surface of circular member 13 is provided with a plurality of circumferentially spaced channels 20 ( FIG. 12 ).
Referring to FIG. 1B and in particular FIGS. 8-9D , the driver 10 includes a sleeve 21 having an elongated, hollow, generally cylindrical body 22 with circumferentially spaced outwardly projecting flanges 23 positioned to be received in the channels 20 ( FIG. 21 ). Formed along the inner surface of the sleeve 21 , at circumferentially spaced locations, is a plurality of longitudinally extending channels 24 ( FIGS. 9A and 9D ). The cylindrical body 22 has a tapered hexagonal shaped in transverse cross section end wall 25 with an axial bore 26 formed therethrough. The inner surface of sleeve 21 includes threads 27 at its upper and open end ( FIGS. 8 and 9D ). During assembly, sleeve 21 is coaxially received in the stem portion 15 of the driver, with hexagonally shaped sleeve end wall 25 mateably seated in the hexagonally shaped body end wall 17 , ( FIG. 1B ) and flanges 23 mateably received in the channels 20 ( FIGS. 1B and 21 ) thereby preventing rotation of sleeve 21 relative to body 12 .
As shown in FIGS. 2C and 5 , the driver 10 includes an elongated shaft 14 with a fastener-engaging portion 16 at one end. The shaft portion above the engaging portion is hexagonal shaped in transverse cross section. Intermediate to its ends, shaft 14 includes a circumferential groove 30 , operably configured to receive a retaining ring 31 ( FIGS. 2C and 5 ). At the end opposite of the fastener-engaging portion 16 , the shaft 14 includes a bearing end face 32 configured for engagement with a ball bearing 33 . During assembly, the shaft 14 is passed through aligned bores 19 and 26 in the driver stem 15 and sleeve 21 respectively, with the retaining ring 31 seated on the inner surface of sleeve end wall 25 ( FIG. 5 ).
Referring to FIGS. 5-7 , the driver 10 includes torque-limiting means, which may comprise an upper non-rotational cam 40 , a lower rotational cam 41 , and a compression spring 42 . More particularly, upper cam 40 includes an annular body 43 and a cylindrical bore 44 formed axially therethrough. On the outer surface of annular body 43 are circumferentially spaced outwardly projecting splines 45 . The upper cam 40 has an upper face 48 and a lower face comprised of circumferentially spaced teeth 45 , each having a sloping face 46 and an axial face 47 . The lower cam 41 includes an elongated cylindrical portion 49 at one end and an elongated location boss portion 50 at the other. Intermediate and integral with the two portions 49 and 50 is a radially extending annular body 51 that includes a lower face 52 and an upper face comprised of circumferentially spaced teeth 53 , each having a sloping face 54 and an axial face 55 . A hexagonal bore 56 dimensioned to mateably receive shaft 14 is formed through the lower cam 41 .
Referring to FIGS. 2B , 2 C and 5 , during assembly, the lower cam 41 is fitted over the shaft 14 within the sleeve 21 with the lower face 52 seated on a thrust washer 57 , which is seated on the sleeve wall 28 . When assembled, the hexagonal bore 56 acts in concert with the hexagonal shaft 14 to prevent rotation of the shaft 14 relative to lower cam 41 . The upper cam 40 is then fitted down coaxially over the upper end of shaft 14 and within sleeve 21 such that the outwardly projecting splines 45 are mateably received by the longitudinal channels 24 on the inner surface of the sleeve ( FIGS. 8A and 9D ) and the teeth 45 of the upper cam are mateably engaged with the teeth 53 of the lower cam 41 . In such an orientation, the upper cam 40 is prevented from rotation relative to the sleeve 21 . And the relative rotation of the upper and lower cams 40 and 41 is prevented in one direction due to the engagement of the axial faces 47 of the teeth 45 with the axial faces 55 of the teeth 53 of the of the upper and lower cams respectively. However, relative rotation of the upper and lower cams 40 and 41 is provided in the opposite direction due to the engagement of the sloping faces 46 of the teeth 45 with the sloping faces 54 of the teeth 53 of the upper and lower cams respectively. Lastly, the torque-limiting means is completed by coaxially fitting the compression spring 42 over the upper end of the shaft 14 , within the sleeve 21 , and seated on the upper face 48 of the upper cam 40 .
The driver 10 includes a torque-adjustment means, which comprises an annular adjustment plug. Two embodiments are described. The first embodiment is shown in FIGS. 1B and 1C , and in particular FIGS. 13-13D . Here the adjustment plug 60 has an annular body 61 with an externally threaded surface 62 , a lower end face 63 , an upper end face 64 and a cylindrical axial bore 65 therethrough. The upper end face 64 is further characterized by an elongated key structure 66 , in this embodiment, a twelve point star formation. The second embodiment of the adjustment plug is shown in FIGS. 2B , 17 and in particular FIGS. 18-18D . Here the adjustment plug 67 has an annular body 68 with an externally threaded surface 69 , a lower end face 70 , an upper end face 71 , and a keyway structure 72 therethrough, in this embodiment, an octagonal bore. During assembly, the adjustment plug 60 or 67 is fitted coaxially over the upper end of the shaft 14 , and threadedly engaged in the upper open end of the sleeve 21 , for bearing against the upper end of the compression spring 42 . The extent to which the adjustment plug 60 or 67 is threaded into the sleeve 21 controls the amount of compression on the spring 42 , which, in turn, controls the force with which the upper cam 40 is driven into engagement with the lower cam 41 . Thus, the limiting torque required to effect the relative rotation of the upper and lower cam can be set to a desired torque value. To effect the threading of the adjustment plug to the desired position, a socket wrench or the like can be used to engage the key or keyway structure, 66 and 72 respectively.
To maintain the desired torque value, the driver 10 includes a torque-locking means, which comprises a locking plate coupled with the adjustment plug and the driver body to prevent the inadvertent movement of the adjustment plug. Again, two embodiments of the locking plate are described to coincide respectively with the two previously described adjustment plug embodiments. The first embodiment is shown in FIGS. 1B , 5 and in particular FIGS. 14-14D . The locking plate 75 has a generally diamond shape and includes an adjustment plug-engaging portion 76 and a body-engaging portion 77 . The plug-engaging portion 76 is characterized by a bored keyway structure 78 , in this embodiment, a twelve point star formation to mateably receive the adjustment plug 60 ( FIGS. 15 and 16 ). The body-engaging portion 77 is characterized by serrations 79 located at opposite ends of the plate 75 , in this embodiment, six serrations per end. The second embodiment of the locking plate is shown in FIGS. 1B , 17 , 21 , and in particular FIGS. 19-19D . Here the locking plate 80 is generally T-shaped and includes an adjustment plug-engaging portion 81 , a body engaging portion 82 , and a cylindrical bore 83 formed axially therethrough. The plug-engaging portion 81 is characterized by an elongated key structure 84 , in this embodiment, a twelve point star formation to mateably receive the adjustment plug 67 ( FIGS. 17 and 20 ). The body-engaging portion 85 is characterized by serrations 86 located at opposite ends of the plate 80 , in this embodiment, six serrations per end. To receive the body-engaging portions of the locking plates 75 and 80 , the body 12 of the driver 10 , and in particular the upper surface of the generally circular upper member 13 , includes locking plate-engagement portions 89 ( FIG. 12 ). In the embodiment shown in FIG. 12 , the locking plate-engagement portions 89 include serrations 87 which are shown integral with the cap location bores 88 to receive the body-engagement portions 77 and 82 respectively ( FIGS. 16 and 21 ). In FIG. 12 , the locking plate-engagement serrations 87 are shown integral with only two of the cap location bores 88 , but it should be appreciated that the engagement serration may be associated with the other cap location bores for even finer adjusting and locking means.
Referring to FIGS. 1B , 1 C and 16 , during assembly of the first embodiment of the torque-locking means, locking plate 75 is fitted coaxially over the upper end of shaft 14 , the bored keyway structure 78 of the plug-engagement portion 76 is mateably received by the elongated key structure 66 of the adjustment plug 60 , and the serrations 79 of the body-engaging portion 77 are received by the locking plate-engagement serrations 87 of the upper generally circular member 13 such that the adjustment plug is locked in position. Referring to FIGS. 2B , 2 C, 17 and 21 , during assembly of the second embodiment, the locking plate 80 is fitted coaxially over the upper end of the shaft 14 , the elongated key structure 84 of the plug-engagement portion 81 is mateably received by the keyway structure 72 of the adjustment plug 67 , and the serrations 86 of the body-engaging portion 85 are received by the locking plate-engagement serrations 87 of the upper generally circular member 13 such that the adjustment plug is locked in position.
The preferred embodiment of the driver 10 is shown in FIGS. 3A-3C . Referring to FIGS. 3B and 3C , the driver includes a third embodiment of the torque-locking means which comprises a locking plate coupled with the adjustment plug and the sleeve to prevent the inadvertent movement of the adjustment plug. The third embodiment of the locking means utilizes the adjustment plug 67 previously shown in FIGS. 2B , 17 and in particular FIGS. 18-18D . To restate briefly, the adjustment plug 67 has an annular body 68 with an externally threaded surface 69 , a lower end face 70 , an upper end face 71 , and a keyway structure 72 therethrough, in this embodiment, an octagonal bore. Referring to FIGS. 3B and 3C , during assembly, the adjustment plug 67 is fitted coaxially over the upper end of the shaft 14 , and threadedly engaged in the upper open end of the sleeve 29 , for bearing against the upper end of the compression spring 42 . Sleeve 29 is similar to the sleeve 21 previously described, but includes a pair of prongs 29 A located on opposite sides of the upper open end of the sleeve ( FIGS. 10-11D ). The locking plate utilized in the third embodiment of the torque-locking means is shown in FIGS. 3B , 3 C, and in particular FIGS. 23A-23E . The locking plate 100 is generally gear shaped and includes an adjustment plug-engaging portion 101 , a sleeve engaging portion 102 , an annular cap-receiving portion 107 , and a cylindrical bore 103 formed axially therethrough. The plug-engaging portion 101 is characterized by an elongated key structure 104 , in this embodiment, an eight point star formation to mateably receive the adjustment plug 67 ( FIGS. 3B and 22 ). The sleeve-engaging portion 102 is characterized by gears 105 about its circumference with undulations 106 to mateably receive the locking plate-engagement portions 29 B, which include prongs 29 A on the upper end of the sleeve 29 ( FIG. 24 ).
Referring to FIGS. 3B , 3 C, 22 and 24 , during assembly of the third embodiment, the locking plate 100 is fitted coaxially over the upper end of the shaft 14 , the elongated key structure 104 of the plug-engagement portion 101 is mateably received by the keyway structure 72 of the adjustment plug 67 , and the undulations 106 of the sleeve-engaging portion 102 are received by the locking plate-engagement prongs 29 A on the upper end of the sleeve 29 such that the adjustment plug is locked in position.
To complete the assembly of the driver 10 , a gripping means comprising a cap 18 with a grippable surface 95 and a cushion and/or label 96 ( FIGS. 1A and 1C ) is mounted to the generally circular member 13 . During assembly, a ball bearing 33 is seated in the ball support 91 of the cap 18 ( FIG. 17 ), and the cap is then fitted over the upper generally circular member 13 , to a mounted position shown in FIGS. 5 and 17 . In the mounted position, the ball bearing 33 is held against the bearing end face 32 of the shaft 14 and the location posts 92 ( FIG. 17 ) are mateably received in the cap location bores 88 ( FIGS. 12 and 17 ). The cap may be snap-fitted to the generally circular member 13 , or fixed by sonic welding, solvent welding or the like. When the cap is fixed, the driver is permanently assembled with the torque setting locked in the desired position.
Finally FIG. 27 shows a golf club weight attachment system 100 whereby a lockable torque-limiting driver 10 is locked at a desired torque setting as described above is used with a weight adjustable golf club 101 (as well known in the art) with weights 102 that are screwably attached at locations 104 on the club 101 . The weights 102 are attached to the club 101 by inserting the weight-engaging tip 16 A of the shaft 14 into the weights 102 and then screwably attaching them at locations 104 (at the desired torque setting) so that the desired weight characteristics of the club are realized. See below for a detailed description of the operation of the driver 10 .
Operation of the driver 10 is accomplished by the taking the cap 18 into the user's hand such that the palm rests on the upper surface of the cap and the fingers rest within the grippable surface 95 . In addition to the generally circular driver previously described, the driver 10 may also be substantially T-shaped, and example of which is shown in FIGS. 25 and 26 . For the T-shaped embodiment, it will be appreciated that the inner workings are the same as previously described for the generally circular embodiment and, in operation, the arms 110 of the driver may be rested in the palm of the user's hand, with the fingers wrapped beneath the arms and straddling the stem potion 111 . When the driver in either embodiment is rotated in one direction, the shaft 14 will rotate with the body 12 until the desired torque level is reached, at which point the biasing force exerted by the spring 42 is overcome to allow the sloping faces 46 of the upper cam 40 to slide up the sloping faces 54 of the lower cam 41 for the angular distance of one tooth, at which point the upper cam 40 will snap into engagement behind the next tooth of the lower cam 41 , thereby provide the user a tactile and/or audible indication that the desired torque has been reached.
In the construction of the driver 10 , a majority of the components may be formed of suitable plastics that may be molded, however, components that must withstand load bearing, torsional, and other significant forces such as the retaining ring 31 , spring 42 , shaft 14 and ball bearing 33 may be formed of suitable metals. Based on the forgoing description and accompanying figures, it can be seen that there has been provided an improved lockable torque-limiting driver that allows for a fine range of torque setting such that it can be effectively locked into a variety of specific torque settings. It has also been shown that the driver can be produced at a low-cost and is suitable for mass production without sacrificing precision. | A lockable torque-limiting driver that includes, a body, a sleeve, a shaft carried by the body for rotation relative thereto and having a fastener-engaging tip at one end that projects from the body, a torque-limiting mechanism coupled to the shaft and housed within said body, a torque-adjusting mechanism within the body and coupled to the torque-limiting mechanism for adjusting the torque-limiting mechanism to a desired torque value, a torque-locking mechanism operably coupled with the torque-adjusting mechanism and the body or the sleeve for preventing movement of the torque-determining means and locking the settable torque-limiting driver at the desired torque value. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to leg protection. More specifically, the invention relates to a shin guard, particularly for use by wearer involved in combat sports.
BACKGROUND
[0002] Shin guards are worn in a variety of sports to protect the lower legs of the wearer during competition and training. It is important that shin guards offer proper protection, while still being comfortable and lightweight without restricting the mobility of the wearer. The most commonly known type of shin guard consists of a resilient material, such as foam, strapped to the lower legs. This basic shin guard is lightweight and does not unduly restrict the mobility of the wearer. However, most commonly known shin guards are not concerned with protecting the opponent.
[0003] While the primary purpose of shin guards is to protect the wearer from accidental blows or impacts during sports, such as soccer or hockey, and in combat sports such as kickboxing, mixed martial arts, jiu-jitsu, and wrestling, it is also important to consider the comfort and safety of the opponent and to reduce the likelihood of the shin guard catching on clothing or causing abrasions to both the wearer and the opponent. In such combat sports blows or impacts are more common due to the nature of the activity, particularly since kicking the opponents legs may be allowed, or intentional, and the shin may be used for striking and blocking. Furthermore, in such combat sports it is also desirable to provide protection to the instep of the wearer as the instep may be used for striking.
[0004] There are various means known for securing shin guards to the wearer. For the soccer-type shin guard, the shin guard may be placed beneath a sock or within a pocket in a sock. For other shin guards resilient straps may be used that are either separate or incorporated as encircling the shin guard. However, these rigid shin guards are not well-suited for combat sports. There is a need for shin guards that are suited for combat sports and overcome the problems of the shin guards designed for other sports.
SUMMARY OF THE INVENTION
[0005] Accordingly, there is a need for a shin guard for use in combat sports that, while providing the requisite protection and mobility to the wearer, also provides for reduced irritation to both the wearer and the opponent(s).
[0006] In particular, the shin guard has a front padding attached to a sleeve along most of its length, except for a top portion of the front padding adjacent the wearer's knee that is reversibly attachable. A closure system at the top of the sleeve, which secures the shin guard to the leg of the wearer, is hidden beneath the top portion of the front padding. When the front padding is secured, the closure system is hidden and is unlikely to catch on clothing or cause irritation.
[0007] In an embodiment of the present invention, there is provided a shin guard comprised of a sleeve and having a top portion, a bottom portion, a front portion, and a back portion, the front and back portions each having atop portion and a bottom portion. There is front padding attached to the front of the sleeve along its length from the instep up toward the top, except for a top portion of the front padding adjacent to the knee. The unattached portion of padding is reversibly secured to the sleeve and covers a closure system at the top of the sleeve. The shin guard also has a foot loop for maintaining the position of the shin guard.
[0008] In another aspect, the sleeve is an elastic material or a neoprene material.
[0009] In a further aspect, the shin guard also has a calf reinforcement affixed to the back portion of the sleeve. As a further option, the calf reinforcement is cross-shaped. The calf reinforcement may be made of a material less elastic than the sleeve material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Embodiments will now be described, by way of example only, with reference to the attached Figures, wherein:
[0011] FIG. 1 is a front elevation perspective view of a shin guard showing the closure system open and unsecured and the top region of the front padding secured in accordance with an embodiment of the present invention.
[0012] FIG. 2 shows the shin guard shown in FIG. 1 with the closure system and top region of the front padding both open.
[0013] FIG. 3 shows the shin guard shown in FIGS. 1 and 2 with the closure system tightened and secured with the top region of the front padding open.
[0014] FIG. 4 shows the shin guard shown in FIGS. 1 , 2 , and 3 with the closure system tightened, secured, and hidden behind the secured front padding; and
[0015] FIG. 5 shows a shin guard having an optional calf reinforcement according to a further embodiment of the present invention.
DETAILED DESCRIPTION
[0016] The present invention provides a shin guard having a hidden closure system that reduces the likelihood of the closure catching on clothing and causing irritation. The preferred embodiment will now be described with reference to the figures wherein like elements are identified by like numbers.
[0017] A shin guard in accordance with the present invention will now be described in detail with reference to the figures. The shin guard 10 is shown in FIG. 1 on the leg 5 of the wearer in an unsecured configuration. The sleeve 11 has a top portion near the knee of the wearer, a bottom portion near the ankle of the wearer. The sleeve 11 also has a front sleeve portion (not clearly shown of FIG. 1 because of the front padding 15 ) extending along the length of the sleeve from the top sleeve portion to the bottom sleeve portion. The front sleeve portion includes: a front top portion being near the knee of the wearer; a front bottom portion (not clearly shown of FIG. 1 ) being near the instep of the foot of the wearer and extending along the length of the sleeve; a back top portion near the knee of the wearer; a back bottom portion near the heel of the foot of the wearer; and two opposing sides of the front sleeve portion extending along the length of the sleeve and joining the front portion of the sleeve with the back portion of the sleeve. Thus, the sleeve 11 is a tubular form, similar to a sock. In a preferred aspect, the sleeve 11 is form fitting and elastic. Any suitable material or fabric may be used to construct the sleeve 11 ; however, a neoprene material is particularly preferred. In some aspects, the sleeve 11 is fabricated as a composite of different materials but is preferably made from a single material.
[0018] On the front of the sleeve 11 is front padding 15 . The front padding 15 has an instep region 15 a covering at least a portion of the instep of the wearer and a shin region 15 b covering a portion of the shin of the wearer from at or near the ankle and toward the mid-area or the top of the shin. The instep region 15 a and the shin region 15 b are attached, or affixed to the front of sleeve 11 and are also flexibly connected to one another to allow the wearer of shin guard 10 to flex and extend their foot. The front padding 15 also has top region 15 c covering a top portion of the shin and unlike the instep region 15 a and the instep region 15 b , may be selectively and adjustably attached to the sleeve 11 by a fastening system.
[0019] It should be mentioned that the front padding may be partially or fully removable from the sleeve. In other words, the top region 15 c may be pulled away from the sleeve 11 .
[0020] The fastening system may be any suitable system for selectively and reversibly attaching the top region 15 c of the front padding 15 . The preferred fastening system is hook-and-loop, such as a Velcro® system, with complementary hook-and-loop surfaces on the inside of the top region 15 c of the front padding 15 and the front top portion of sleeve 11 . The front padding 15 may be constructed of any suitable materials or fabrics. In some aspects, the front padding 15 is constructed of an outer covering layer which, for example, may be made of a leather or polyurethane material, or of a combination of synthetic and real leather materials that enclose an impact absorbing material.
[0021] The shin guard 10 has a closure system 17 (that is shown in an unsecured state in FIG. 1 ) at the top of sleeve 11 for selectively and adjustably tightening and securing the shin guard 10 on the leg of the wearer. The closure system may be any suitable system for selectively and adjustably tightening and securing the shin guard 10 on the leg of the wearer. A preferred closure system is a strap configured to tighten the sleeve when the strap is pulled and having hook-and-loop surfaces complementary to the hook-and-loop surfaces affixed to the front padding 15 c and the front top portion of the sleeve 11 and the top region 15 c of the front padding 15 . In such a configuration, when the closure system 17 is engaged to tighten and secure the shin guard 10 on the leg of the wearer, and when the front padding 15 c is secured to the sleeve 11 , the closure system 17 is fully enclosed between the front padding 15 c and the sleeve 11 , thereby preventing the closure system from catching on clothing, from causing skin irritation or damage, or from becoming unsecured during use (not shown in FIG. 1 ).
[0022] The shin guard 10 also has at least one foot loop 18 (not fully shown in FIG. 1 ) attached to, or extending from, the bottom of the sleeve 11 . The foot loop 18 partially wraps around the foot of the wearer to help maintain the position of shin guard 10 during use, primarily to prevent the shin guard 10 from rising up. The foot loop 18 is preferably positioned to wrap around the arch of the foot of the wearer. The foot loop 18 may be made of any suitable material or may be made of the same material as the sleeve 11 .
[0023] FIGS. 2 , 3 , and 4 show the stepwise process of securing the closure system 17 and securing the top region 15 c of the front padding 15 over top of securing the closure system 17 , thereby enclosing the closure system 17 . The complementary hook-and-loop surfaces on the inside of the top region 15 c of the front padding 15 and the front top portion of the sleeve 11 are shown as the cross-hatched areas (in FIGS. 2 and 3 ).
[0024] FIG. 2 shows the closure system 17 in an open and unsecured state with the top region 15 c of the front padding 15 also open and unsecured. The first large arrow descending from the knee area of the wearer indicates the direction of pulling the wearer may exert on top region 15 c before tightening the closure system 17 .
[0025] FIG. 3 shows a closure system 17 tightened and secured by pulling the strap of closure system 17 in the direction of the second large arrow. Top region 15 c of front padding 15 is shown open and unsecured.
[0026] FIG. 4 shows a top region 15 c of the front padding 15 secured over top of the closure system 17 by pulling the top region 15 c in the direction of the third large arrow.
[0027] As shown in FIG. 5 and according to a further optional embodiment of the present invention, the shin guard 10 also has a calf-reinforcement 19 in an optional embodiment of the present invention on the back bottom of sleeve 11 to add support to the shin guard 10 , particularly for repeated flexing and extension of the wearer's foot, and specifically to support the calf of the wearer. Calf-reinforcement 19 may be of any suitable material but is preferably less elastic than the sleeve 11 material. Calf-reinforcement 19 is preferably affixed over the sleeve 11 on the outward facing surface and in another preferred embodiment is cross-, or X-shaped.
[0028] During testing, the present invention has been found to be particularly effective at providing support to the calf of the wearer.
[0029] The above-described embodiments are intended to be examples of the present invention and alterations and modifications may be effected thereto, by those of skill in the art, without departing from the scope of the invention which is defined solely by the claims appended hereto, which should be given the broadest interpretation consistent with the description as a whole. | A shin guard for combat sports is provided having increased protect for the wearer and the opponent. The shin guard has sleeve for surrounding the lower leg of the wearer and a front padding attached to the sleeve with a top portion reversibly secured which covers and hides a closure system. The shin guard may also have a calf reinforcement. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of International Application No. PCT/EP2008/008864 (Publication No. WO 2010/045950 A1), filed Oct. 20, 2008, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The invention is directed at the building up of objects and, in particular, to the building up of objects that are intended to be used for dental restorations.
BACKGROUND OF THE INVENTION
CAD-CAM technologies have been established in the dental sector for some time and have taken the place of the traditional manual crafting of tooth replacements. However, the methods customary today for producing ceramic dental restoration elements by removing material have several disadvantages, which cannot be improved with reasonable expenditure from economic aspects by the current state of the art. In this connection, building-up methods of production that are known under the term “rapid prototyping” can be considered, in particular stereolithographic methods in which a newly applied layer of material is respectively polymerized in the desired form by position selective exposure, whereby the desired body is gradually produced by shaping in layers in its three-dimensional form, which results from the succession of the layers applied.
With respect to ceramic-filled polymers, WO 98/06560, which is hereby incorporated by reference, should be mentioned in particular. In this case, a ceramic slip is exposed by way of a dynamic mask (light modulator), whereby a three-dimensional body is intended to be gradually built up. In the case of the method described, the ceramic slip is exposed from above on a build platform. In the case of such exposure from above, after each exposure a new thin layer of material must be applied with the aid of a doctor blade (typically with a layer thickness which lies between 10 and 100 μm). When using materials of relatively high viscosity, as ceramic-filled resins are, it is only with difficulty, however, that such thin layers can be applied in a reproducible manner.
In the prior art, there are also known techniques, at least for photomonomers without ceramic filling, in which the exposure takes place from below through the bottom of a vat, which is formed by a transparent film, sheet or sheet with an elastomeric surface (for example of silicone or fluoroelastomer). Above the transparent film or sheet there is a build platform, which is held at a settable height above the film or sheet by a lifting mechanism. In the first exposure step, the photopolymer between the film and the build platform is polymerized in the desired form by exposure. When the build platform is raised, the polymerized first layer becomes detached from the film or sheet and liquid monomer flows into the space created. The object polymerized in layers is created by successive raising of the build platform and selective exposure of the monomer material that has flowed in. A device suitable for applying this method is described for example in DE 199 57 370 A1, which is hereby incorporated by reference. A similar procedure is described in DE 102 56 672 A1, which is hereby incorporated by reference, which however likewise relates to unfilled polymers.
In the processing of ceramic-filled photopolymers, the following problems arise in comparison with the processing of unfilled photopolymers:
The green strength of the polymerized objects is significantly lower (less than 10 MPa) than the strength of an unfilled polymer (typically about 20 to 60 MPa). As a result, the ceramic-filled photopolymer object can withstand significantly less mechanical loading (for example when the last-formed layer is detached from the sheet or film through which exposure was performed from below). The high proportion of ceramic particles causes pronounced light diffusion, and the depth of penetration of the light that is used is significantly reduced. Associated with this is non-uniform polymerization in the z direction (direction of radiation) in the case of layer thicknesses of more than 20 μm. The small depth of penetration also makes it difficult to achieve reliable bonding of the first layer directly on the build platform. In the case of ceramic-filled monomer material, however, it cannot be ensured that the initial starting layer is sufficiently thin (for example less than 75 μm). Consequently, a reproducible bonding force on the build platform could not be ensured even with very long exposure of the first layer. In comparison with unfilled photopolymers, ceramic-filled polymerizable materials are significantly more viscous. This imposes increased requirements on the exposure mechanism that is used. In particular, the time that is required for ceramic-filled photopolymer to flow in after raising of the build platform may be considerably longer. The raising and lowering of the build platform in a highly viscous photopolymer material also imposes increased requirements to avoid detrimental effects on the component. On account of the high basic viscosity, ceramic-filled photopolymers are more sensitive to gelling by diffused light or ambient light. Even small light intensities are sufficient to raise the viscosity of the material above the permissible limit by the polymerization taking place.
The problem addressed by the present invention is that of improving a building method and a device for processing light-polymerizable materials for building up objects, using lithographic rapid prototyping, in such a way that they allow even light-polymerizable materials of relatively high viscosity, in particular ceramic-filled photopolymers, to be processed better.
SUMMARY OF THE INVENTION
The device and methods according to the independent patent claims serve for solving this problem. Advantageous embodiments of the invention are specified in the subclaims.
The invention relates to a device for processing light-polymerizable material for building up an object in layers, using lithography-based generative fabrication, for example rapid prototyping, with a vat with an at least partially transparently or translucently formed horizontal bottom, into which light-polymerizable material can be filled, a horizontal build platform which is held at a settable height above the vat bottom, an exposure unit, which can be controlled for position selective exposure of a surface on the build platform with an intensity pattern with predetermined geometry, a control unit, which is arranged for polymerizing in successive exposure steps layers lying one above the other on the build platform, respectively with predetermined geometry, by controlling the exposure unit and for adjusting, after each exposure step for a layer, the relative position of the build platform to the vat bottom, in order in this way to build up the object successively in the desired form, which results from the sequence of the layer geometries.
The invention also relates to a method for processing light-polymerizable material for building up an object, using a lithography-based generative fabrication technique, for example rapid prototyping, in which a layer of a light-polymerizable material which is located in at least one vat with an in particular transparently or translucently formed, horizontal bottom is polymerized on at least one horizontal build platform, protruding into at least one vat, with predetermined geometry by exposure in an exposure area, the build platform is displaced vertically for the forming of a subsequent layer, light-polymerizable material is newly fed onto the layer last formed, and, by repeating the previous steps, the object is built up in layers in the desired form, which results from the sequence of the layer geometries.
BRIEF DESCRIPTION OF THE FIGURES
Further advantages, details and features emerge from the following description of embodiments of the invention on the basis of the drawings, in which:
FIG. 1 shows a lateral plan view, partly in section, of a device according to the invention,
FIG. 2 shows a plan view of the device from FIG. 1 , from above,
FIGS. 3 to 5 show a partial view of the device from FIG. 1 in the region of the build platform and the vat bottom in successive working steps,
FIG. 6 shows a plan view from above of a second embodiment of the invention,
FIG. 7 shows a lateral plan view, partly in section, of the device of the second embodiment from FIG. 6 , and
FIG. 8 shows a plan view from above of a third embodiment of the device.
DETAILED DESCRIPTION OF THE INVENTION
The device according to the invention is characterized in that the vat is horizontally movable with respect to the exposure unit and the build platform and in that a feed device is provided and, under the control of the control device, discharges light-polymerizable material into the vat, the exposure unit and the build platform being arranged horizontally at a distance from the feed device, and in that the control unit is arranged for moving the vat between successive exposure steps in a prescribed way into a horizontal plane by a drive in order to bring light-polymerizable material that has been discharged in this way by the feed device onto the vat bottom into the region between the exposure unit and the build platform.
In a preferred embodiment, arranged between the feed device and the exposure unit/build platform in the direction of movement of the vat is an application device, in particular a doctor blade or a roller, the height of which above the vat bottom can be set, in order to act on the layer of light-polymerizable material discharged by the feed device and bring it to a uniform thickness before it reaches the intermediate space between the exposure unit and the build platform.
In a preferred embodiment, the exposure unit is arranged below the vat bottom for exposure of the at least partially transparent or translucent vat bottom from below, and the build platform is held in a lifting mechanism above the vat bottom in a manner in which it can be adjusted in height by the control unit.
Preferably, the control unit is arranged for setting the thickness of the layer, to be specific the distance between the build platform or the layer last formed and the vat bottom, by means of the lifting mechanism.
In the lifting mechanism, and connected to the control unit, there is preferably a force transducer, which is capable of measuring the force exerted by the lifting mechanism on the build platform and sending the measurement result to the control unit, the control unit being arranged for moving the build platform with a prescribed force profile. In particular in the case of ceramic-filled light-polymerizable materials, on account of the high viscosity, great forces may occur when the build platform is moved down into or moved up out of the viscous material, caused by the viscous material being displaced from or sucked in between the build platform and the vat bottom. In order to limit the forces occurring and nevertheless allow the highest possible lowering and raising rates, which speeds up the production process as a whole, the control unit may use the lifting mechanism optimally in a force-controlled manner by force measurement.
To perform the horizontal movement between successive exposure steps, the vat may be mounted with its bottom rotatable about a central axis and be turned by a prescribed angle by a drive between successive exposure steps. The exposure unit and the build platform lying above it lie offset radially outward with respect to the central axis, so that in successive exposure steps and rotational movement steps taking place in between the vat bottom is ultimately passed over in the form of a circular ring. The application device, for example a doctor blade or roller or combinations thereof, then lies between the feed device on the one hand and the exposure unit and the build platform on the other hand in the direction of movement, so that the exposure process takes place after the application device has acted on the layer of material. Multiple doctor blades or rollers or combinations thereof may be provided in order to have a smoothing and rolling effect on the layer. The application device may also be formed in particular by an edge of a discharge channel of the feed device, which lies at a settable height above the vat bottom.
As an alternative to the rotational movement, the vat may be mounted such that it can be moved in a line and a drive that is capable of moving the vat by a prescribed distance between successive exposure steps under the control of the control unit may be provided.
By suitable choice of the size of the movement steps of the vat, strategies which allow the vat bottom to be exposed at new places each and every time can be carried out, so that adhesive attachment of the light-polymerizable material to the vat bottom caused by repeated exposure of the same place on the vat bottom can be reduced. In a rotational movement of the vat, for example, the ratio of full circle)(360° to rotational angle increment is preferably not an integral number, in particular also not a rational number. Alternatively, the rotational angle increments may also be varied in a prescribed or random manner, so that the polymerization always takes place in different regions of the vat.
Light-emitting diodes are preferably used in the device as the light source of the exposure unit and/or of the further exposure unit. Conventionally, mercury vapor lamps have been used in the case of stereolithography processes with mask projection, which however entails disadvantages since the luminous density of such mercury vapor lamps can vary considerably over time and space, which often makes repeated calibrations necessary. It is therefore preferred to use light-emitting diodes, which show significantly lower variations in intensity over space and time. Nevertheless, in a preferred embodiment, the device is arranged for carrying out a correction or compensation of variations in intensity automatically at prescribed intervals. For this purpose, it may be provided that the exposure unit has a reference sensor, which is formed as a photosensor scanning the entire exposure area or as a CCD camera recording the entire exposure area. The control unit is arranged for operating in a calibration step by exposing the exposure unit above the exposure area with a control signal for the exposure unit that is prescribed over the entire exposure area and using the intensity pattern recorded by the reference sensor in the case of the prescribed control signal for calculating a location-dependent compensation, the application of which produces a uniform intensity in the entire exposure area. In other words, the compensation mask delivers location-dependently in the exposure area a relationship between the signal amplitude controlling the exposure unit and the actual intensity respectively resulting from this. This allows time-dependent or permanently occurring variations of the locational intensity distribution in the exposure area to be compensated, by the exposure unit being controlled location-dependently by the control unit with a mask inverse to the intensity pattern actually recorded in the case of the prescribed control signal in the last calibration step, so that a uniform actual intensity can be achieved in the exposure area.
Light-emitting diodes which emit light with different optical wavelengths are preferably used. This makes it possible to process different materials with different photoinitiators in the same device.
The exposure unit is preferably designed for the emission of light with an average intensity of 1 mW/cm 2 to 2000 mW/cm 2 , in particular 5 mW/cm 2 to 50 mW/cm 2 .
The exposure unit preferably has a spatial light modulator, in particular a micromirror array controlled by the control unit.
In a preferred embodiment, behind the region of the exposure unit and the build platform there lies a wiper which can be positioned at a prescribable height above the vat bottom and is designed for renewed distribution of the material after the polymerization process. After an exposure step and after the build platform has been raised, a zone without light-polymerizable material, corresponding to the form of the layer last formed, is left behind in the layer of material on the vat bottom. This zone is filled again at the latest when it is passed by the wiper, by renewed distribution of the material on the vat bottom.
The device is preferably designed for the purpose of performing a relative tipping movement between the build platform and the vat bottom when the raising of the build platform is initiated after an exposure step, under the control of the control unit, whereby a more gentle separation of the layer of polymerized material from the vat bottom is achieved, and consequently less stress on the object.
In a preferred embodiment there are a plurality of vats, each of which is assigned a feed device for one of a plurality of light-polymerizable materials, and a drive, which, under the control of the control unit, is capable of moving one of the vats in each case in a selected prescribed sequence between the exposure unit and the build platform, this movement being a linear movement in the case where multiple vats are arranged in series or a rotating movement in the case where multiple vats are arranged along a curved path, whereby layers of different materials can be built up in accordance with the selected prescribed sequence. The different materials may differ in their colour and other material properties, in particular optical and mechanical properties, in order in this way to achieve a desired layering of materials in the object. Preferably, when changing from one vat to another, the entrainment of material from one vat into the other vat is suppressed, in order to avoid contamination of the materials in the vats. For this purpose, it may be provided in particular that, after raising from one vat, the build platform with the layers already formed on it is taken through a cleaning device, in particular through a bath with solvent, in order to remove adhering non-polymerized material.
A vat in the sense of the embodiment described in the previous paragraph means a divided, upwardly open receiving space for light-polymerizable material. In particular, therefore, a single vat body may also be divided by separating walls into a number of vat segments that are separate from one another, in order in this way to form a plurality of vats in the sense of this invention.
The feed device preferably has a receptacle for inserting a cartridge with light-polymerizable material, in order to be able in a simple way to use the light-polymerizable material that is desired for the respective building process.
The underside of the build platform is preferably provided with a structuring, for example comprising nubs, channels or grooves, which is provided in or on the lower surface itself and/or in or on a coating or film applied thereto. The at least partially transparent or translucent vat bottom is preferably formed by a film or a sheet containing a polymerization inhibitor. The build platform may, in particular, consist of a high-temperature-resistant material, preferably of zirconium oxide, aluminum oxide, sapphire glass or quartz glass.
A method according to the invention of the aforementioned type is characterized in that the at least one vat can be moved horizontally into a feed position, the feed device discharges light-polymerizable material at least onto an exposure area of the vat bottom before the vat is moved into an exposure position, in which the exposure area is located below the build platform and above the exposure unit, and the exposure takes place.
In a preferred embodiment, the distribution of the fed light-polymerizable material takes place in a prescribed layer thickness on the vat bottom, in particular on the exposure area, while the moving of the vat from the feed position into the exposure position is performed with the aid of an application device, for example a doctor blade or a roller, the height of which above the vat bottom can be set, arranged between the feed device and the exposure unit as well as the build platform.
Preferably, the build platform, possibly with the layers already formed on it is preferably lowered again by the lifting mechanism under the control of the control unit into the newly fed light-polymerizable material, so that light-polymerizable material is displaced from the remaining intermediate space with respect to the vat bottom, and the distance between the lower surface of the layer last formed and the vat bottom is set in a prescribed manner by the control unit. In this way, the thickness of the layer to be formed, which corresponds to the distance between the lower surface of the layer last formed and the vat bottom, can be precisely set by mechanically precise setting of the build platform above the vat bottom.
The first layer of light-polymerizable material is preferably polymerized onto a, possibly removable, film or coating arranged on the underside of the build platform.
The displacement of the build platform preferably takes place by raising and/or lowering under force control in accordance with a prescribed force profile, i.e. the force exerted by the lifting mechanism on the build platform is limited with respect to prescribed criteria. As a result, the forces occurring, which may be considerable, particularly in the case of materials of relatively high viscosity, and could detrimentally affect the buildup of the object, can be limited while nevertheless allowing the highest possible lowering and raising rates of the build platform into and out of the light-polymerizable material, which optimizes the speed of the production process as a whole, since it is possible to work at all times with the highest speed at which detrimental effects are still avoided.
To allow the build up of objects using different materials, a plurality of different materials can be used for building up layers in a selectable sequence in successive layer building steps, by a plurality of vats, each assigned a feed device with one of the plurality of materials, being moved in a selected sequence between the exposure unit and the build platform, this movement being a linear movement in the case where multiple vats are arranged in series or a rotating movement in the case where multiple vats are arranged along a curved path. The different materials may differ in their color and other material properties, in particular optical and mechanical properties, in order in this way to achieve a desired layering of materials in the object.
In a preferred embodiment, a particle-filled, for example ceramic-filled, light-polymerizable material is used for the production of the object and the organic constituents are burned out from the finished object before the object is sintered. The particle fraction of the light-polymerizable material may preferably consist of an oxide ceramic or a glass ceramic.
The light-polymerizable material on the underside of the build platform is preferably polymerized by exposure from below, after which the build platform is raised in relation to a vat for the light-polymerizable material after each exposure step and light-polymerizable material is newly fed under the layer last formed. In this case, the first layer of light-polymerizable material may be polymerized onto a removable film or coating arranged on the underside of the build platform.
The object to be produced by the method according to the invention may be, for example, a green blank for a dental restoration, in which case the light-polymerizable material may be, for example, a ceramic-filled photopolymer. The build platform preferably has a sheet of a high-temperature-resistant material, preferably of zirconium oxide, aluminum oxide, sapphire glass or quartz glass. A transparent polymer film may be adhesively attached on such a ceramic base in order to form the build platform, it being possible for the polymer film to be provided with structurings such as nubs, channels or the like on the side that comes into contact with the photopolymer, in order to achieve better adhesive attachment of the ceramic-filled photopolymer. After the successive buildup of the green blank, the build platform with the green blank adhesively attached thereto can be removed and introduced directly into the sintering furnace. During the debinding of the component, not only the organic resin component but also the polymer film of the build platform decomposes, and after the sintering the sintered ceramic object consequently lies loosely on the sheet of the build platform and can be removed.
In the case of the method according to the invention, a plastic may preferably be used for producing the object, the object being embedded in an embedding compound after it has been produced and burned out after the embedding compound has solidified, and a different material, in particular a dental ceramic material or metal or an alloy, being forced into the cavities created in the embedding compound.
In the case of a preferred method, a dental composite may be used for the production of the object and, after it has been produced, the object may be heat-treated and subsequently polished or coated and subsequently heat-treated.
In the case of a method according to the invention, the ceramic fraction of the ceramic-filled photopolymer preferably consists of an oxide ceramic or a glass ceramic, in particular zirconium oxide, aluminum oxide, lithium disilicate, leucite glass ceramic, apatite glass ceramic or mixtures thereof.
In the case of a method according to the invention, after carrying out an exposure step with the vat stationary, the build platform is preferably raised in order to lift off the layer formed from the vat bottom. For this purpose, a slight relative tipping movement between the build platform and the vat bottom is preferably carried out, since, after the polymerization, adhesive attachment of the layer formed to the vat bottom could lead to excessive mechanical stress on the layer just formed or the entire component if it were pulled vertically upward. After the build platform has been raised, a zone without light-polymerizable material, corresponding to the form of the layer last formed, is left behind in the layer of material on the vat bottom. This zone is filled again at the latest when it is passed by the doctor blade or the roller or by an optional additional wiper, by renewed distribution of the material on the vat bottom.
The following exemplary embodiment relates to the production of a green blank for a dental restoration.
Firstly, the main components of the device are described with reference to FIGS. 1 and 2 .
In the embodiment represented in FIGS. 1 and 2 , the device has a housing 2 , which serves for accommodating and fitting the other components of the device. The upper side of the housing 2 is covered by a vat 4 , which has, at least in the regions intended for exposures, a transparent or translucent and planar vat bottom.
Provided in the housing 2 , under the vat bottom 4 , is an exposure unit 10 , which can, under the control of a control unit 11 , expose a predetermined exposure area on the underside of the vat bottom 6 selectively with a pattern in the desired geometry.
The exposure unit 10 preferably has a light source 15 with multiple light-emitting diodes 23 , a luminous power of approximately 15 to 20 mW/cm 2 preferably being achieved in the exposure area. The wavelength of the light radiated from the exposure unit preferably lies in the range from 400 to 500 nm. The light of the light source 15 is modulated location-selectively in its intensity by way of a light modulator 17 and imaged in the resultant intensity pattern with the desired geometry on the exposure area on the underside of the vat bottom 6 . Various types of so-called DLP chips (digital light processing chips) may serve as light modulators, such as for example micromirror arrays, LCD arrays and the like. Alternatively, a laser may be used as the light source, the light beam of which successively scans the exposure area by way of a movable minor, which may be controlled by the control unit.
Provided over the exposure unit 10 on the other side of the vat bottom 6 is a build platform 12 , which is held by a lifting mechanism 14 with a carrier arm 18 , so that it can be held over the vat bottom 6 above the exposure unit 10 in a height-adjustable manner. The build platform 12 is likewise transparent or translucent.
Arranged above the build platform 12 , which is formed such that it is transparent or translucent, is a further exposure unit 16 , which is likewise controlled by the control unit 11 in order, at least during the forming of the first layer under the build platform 12 , also to irradiate light from above through the build platform 12 , in order thereby to achieve dependable and reliably reproducible polymerization and adhesive attachment of the first polymerized layer on the build platform.
Also provided above the surface of the vat 4 is a feed device 8 with a reservoir in the form of an exchangeable cartridge 9 filled with light-polymerizable material. Under the control of the control unit 11 , ceramic-filled light-polymerizable material can be successively discharged from the feed device 8 onto the vat bottom 6 . The feed device is held by a height-adjustable carrier 34 .
The vat 4 is mounted rotatably about a vertical axis 22 on the housing 2 by a bearing 7 . A drive 24 , which, under the control of the control unit 11 , sets the vat 4 in a desired rotational position, is provided.
A wiper 30 , which can undertake various functions, as explained further below, may be arranged between the exposure unit 12 and the feed device 8 in the direction of rotation, at a settable height above the vat bottom 6 .
As can be seen from FIG. 2 , lying between the feed device 8 and the exposure unit 12 , above the vat bottom 6 , is an application device 26 , here in the form of a doctor blade 26 , which can be positioned at a settable height above the vat bottom 6 , in order in this way to smooth material that has been discharged from the feed device 8 onto the vat bottom 6 by moving past the application device before it reaches the exposure unit 12 , in order thereby to ensure a uniform distribution and prescribed layer thickness. Alternatively or in addition to the doctor blade, one or more rollers or further doctor blades may belong to the application device, in order to act in a smoothing manner on the layer of material.
The pivot arm 18 carrying the build platform 12 is connected by way of a pivot joint 20 to the vertically displaceable part of the lifting mechanism 14 . Also provided in the lifting mechanism 14 is a force transducer 29 , which measures the force exerted by the lifting mechanism 14 on the build platform 12 during the lowering and raising thereof and sends the measurement result to the control unit 12 . As described further below, said control unit is designed for the purpose of controlling the lifting mechanism 14 on the basis of a prescribed force profile, for example to limit the force exerted on the build platform 12 to a maximum value.
The way in which the device represented in FIGS. 1 and 2 functions can be summarized as follows. Under the control of the control unit, a prescribed amount of ceramic-filled light-polymerizable material 5 is discharged from the feed device 8 onto the vat bottom 6 . By controlling the drive 24 , the control unit 11 instigates a turning of the vat bottom 6 about the axis of rotation 22 , so that the discharged material passes the application device 26 , here a doctor blade, which smooths the light-polymerizable material to a prescribed layer thickness 32 , which is determined by the height setting of the application device 26 . Furthermore, by turning of the vat 4 , the material is brought into the region between the build platform 12 and the exposure unit 10 .
After stopping the turning movement of the vat 4 , here there then follows the lowering of the build platform 12 into the layer of light-polymerizable material 5 formed on the vat bottom 6 , which is explained below on the basis of FIGS. 3 to 5 . In the state shown in FIG. 3 , a layer of light-polymerizable material 5 with a prescribed thickness 32 is formed on the vat bottom, the build platform 12 still being located above the layer 5 in this state. Attached to the underside of the build platform 12 is a film 13 , which will be discussed further below. From the state represented in FIG. 3 , a lowering of the build platform 12 then takes place by the lifting mechanism 14 under the control of the control unit 11 , so that the build platform 12 with the film 13 on the underside is immersed into the layer of light-polymerizable material 5 and, as it is lowered further, displaces said layer partially out of the intermediate space between the film 13 and the upper surface of the vat bottom 6 . Under the control of the control unit 11 , the build platform 12 is lowered by the lifting mechanism 14 to the vat bottom in such a way that a layer with a precisely prescribed layer thickness 21 is defined between the build platform and the vat bottom. As a result, the layer thickness 21 of the material to be polymerized can be precisely controlled.
During the immersion of the build platform 12 into the light-polymerizable material 5 and the further lowering into the position shown in FIG. 4 , great forces can occur, particularly when material of relatively high viscosity is displaced, if the lowering of the build platform were to take place at the prescribed rate. In order to prevent the layers of material that build up during the lowering of the build platform 12 into the light-polymerizable material 5 from being exposed to great forces, in the lifting mechanism there is the aforementioned force transducer 29 , which measures the force exerted on the build platform 12 and sends the measurement signal to the control unit 11 . This control unit is arranged for controlling the lifting mechanism in such a way that the force recorded by the force transducer 29 follows prescribed criteria, in particular that the force exerted does not exceed a prescribed maximum force. As a result, on the one hand the lowering of the build platform 12 into the light-polymerizable material 5 and the raising of the build platform out of said material can be carried out in a controlled manner such that the forces exerted on the build platform, and consequently also on the layers already formed, are limited and, as a result, detrimental effects are avoided during the buildup of the object, and on the other hand the lowering and raising of the build platform 12 can be carried out at the maximum possible rate at which detrimental effects on the object to be built up are still just avoided, in order in this way to achieve an optimal process rate.
After the lowering of the build platform into the light-polymerizable material 5 , into the position shown in FIG. 4 , there then follows the first exposure step for the polymerization of the first layer 28 on the build platform 12 , the further exposure unit 16 thereby also being actuated (at the same time or with a time delay), in order to ensure reliable adhesive attachment of the first polymerization layer 28 to the build platform. During the exposure process, the vat 4 is kept stationary, i.e. the drive 24 remains switched off. After the exposure of one layer, the build platform 12 is raised by the lifting mechanism 14 . In this case, however, before the raising of the build platform 12 , a relative tipping movement between the build platform 12 and the vat bottom 6 is preferably carried out first. This slight tipping movement is intended to serve the purpose of detaching the last-polymerized layer of the object 27 from the vat bottom 6 with less mechanical stress. After this tipping movement and detachment of the layer last formed, the build platform is raised by a prescribed amount, as shown in FIG. 5 , so that the layer last formed lies above the light-polymerizable material 5 on the object 27 .
Subsequently, material is again discharged from the feed device 8 and the vat 4 is turned by a prescribed rotational angle by the drive 24 , the material that moves past the doctor blade again being brought to a uniform layer thickness. This series of steps, with the forming of successive layers of a predetermined form of contour, is continued until the succession of layers with respectively predetermined geometry provides the desired form of the ceramic green blank.
The wiper 30 , provided behind the exposure unit and above the vat bottom 6 , may have various functions. For example, when it has been lowered fully onto the vat bottom 6 , it may serve the purpose of collecting the material from the vat bottom and carrying it away or returning it into the feed device 8 , which should take place at the end of a building process. During a building process, when it is raised slightly with respect to the vat bottom 6 , the wiper 30 serves the purpose of distributing the material again, in particular pushing the material back into the “holes” that have been created in the layer of material by the exposure process after raising of the build platform 12 .
After the completion of a building process, the build platform 12 with the exposure unit 16 fitted above it, can be pivoted upward as a whole by pivoting the pivot arm 18 about the joint 20 , as indicated by dashed lines in FIG. 1 . After that, there is better access to the vat 4 , for example to allow the latter to be cleaned or exchanged.
After the described buildup of the green blank from polymerized ceramic-filled material, said blank must be removed from the device and fed to a firing furnace, in which a decomposition of the polymerized binder (debinding) is brought about by the thermal treatment and a sintering of the ceramic material is carried out. To simplify the handling of the built-up body, the build platform is designed such that it can be easily detached from the carrier arm 18 . Then the build platform, with the built-up ceramic-filled object 27 adhesively attached to it, can be removed from its carrier 18 and placed in a firing furnace. In order to allow this preferred simple removal of the built-up dental restoration element of ceramic-filled polymer, the build platform must however be produced from a high-temperature-resistant material, for which zirconium oxide, aluminum oxide, sapphire glass or quartz glass may serve for example. Possible as an alternative to this is a self-adhesive, transparent film, which may be structured with nubs, channels, scores etc. on the side facing the photopolymer, for better adhesive attachment, and can be removed after the building process by simple detachment from the build platform or together with the build platform and passed together with the film into the firing furnace for debinding/sintering.
As compared with the device from FIGS. 1 and 2 with a rotatable vat, FIGS. 6 and 7 show an alternative embodiment, in which the vat 54 is designed such that it is movable linearly back and forth. In this embodiment, a vat 54 is mounted linearly movably on the housing 52 in a bearing 57 . Above the vat 54 , the feed device 58 is arranged in a height-adjustable manner. Offset from the feed device 54 with respect to the linear direction of movement, the build platform 62 is held above the vat 54 on a pivot arm 68 , which belongs to a lifting mechanism 64 . The pivot arm 68 is in turn provided with a pivot joint 70 , which allows the pivot arm 68 , after being raised in the vertical direction, to be turned by 180°, after which the build platform 62 with the object built up on it faces upward, and in this position can be easily handled.
Located below the build platform 62 and the vat bottom 56 is the exposure unit 60 , in which a light source 65 with light-emitting diodes 73 is arranged. The light of the light source 65 is projected by way of a light modulator 67 and through the transparent vat bottom 56 onto the build platform 62 . Also present in the exposure unit 60 is a reference sensor 51 , which is used in a calibration step for the purpose of recording the actual intensity distribution in the exposure area when the light modulator is controlled in such a way as to obviate any locational dependence or modulation over the exposure area. From the deviation of the intensity distribution actually recorded, a control profile (compensation mask) for the light modulator can then be calculated by inversion and provide an intensity that is actually uniform over the exposure area. A corresponding reference sensor 1 is also present in the case of the embodiment from FIGS. 1 and 2 .
Arranged one behind the other in the direction of movement of the vat 54 (indicated by the double-headed arrow in FIGS. 6 and 7 ) are an application device 76 , which is held in a height-adjustable manner above the vat bottom 56 and here is in the form of a doctor blade, the lower edge of which lies at a suitable distance from the surface of the vat bottom, and a wiper 80 .
The way in which the device shown in FIGS. 6 and 7 functions corresponds to the method steps described above with reference to FIGS. 3 to 5 , apart from the difference of the linear movement back and forth of the vat 54 instead of the rotating movement of the vat 4 . Firstly, instigated by the control unit 61 , which actuates the drive 75 , the vat 54 is displaced from the position shown in FIG. 7 to the left into the position shown by dashed lines (feed position). In this case, light-polymerizable material is discharged by the feed device 58 onto the vat bottom 56 , the amount and variation over time of the discharge likewise being prescribed by the control unit 61 . After that, by reversing the drive 75 , the control unit 61 causes the vat 54 to be displaced back again. As this happens, the light-polymerizable material 55 discharged onto the vat bottom 56 first passes the wiper 80 and then the application device 76 , which ensure a uniform distribution and uniform layer thickness of the light-polymerizable material 55 , before it reaches the intermediate space between the build platform 62 and the exposure unit 60 . After that, the drive 75 is stopped, whereupon the series of steps as described above in conjunction with FIGS. 3 to 5 is executed, the build platform 62 being immersed into the layer of light-polymerizable material 55 and a layer with prescribed thickness being defined between the build platform and the vat bottom by setting of the distance from the vat bottom. After that, the actuation of the exposure unit 60 takes place to generate an exposure pattern with predetermined geometry, the further exposure unit 66 with its light-emitting diodes 69 also being actuated in this connection, at least during the generation of the first layer directly on the build platform 62 , in order to expose the first layer by exposure through the transparent or translucent build platform and thereby achieve complete polymerization and reliable adhesive attachment of the first layer to the build platform 62 .
After polymerization of the first layer with the desired geometry, the build platform 62 is raised again by actuating the lifting mechanism 64 , so that the polymerized layer formed is raised above the level of the light-polymerizable material 55 .
After that, the series of steps described is repeated, i.e. the vat 54 is again displaced to the left, light-polymerizable material is discharged from the feed device 58 and this material is distributed uniformly by the wiper 80 and the application device 76 when the vat 54 is pushed back to the right, after which, by switching off the drive 75 , the lifting mechanism 64 lowers the build platform 62 again, so that the last-formed polymerized layer is immersed into the light-polymerizable material 55 and is brought to a prescribed distance above the vat bottom 56 , in order to polymerize the layer of material that is then lying in the intermediate space in the next exposure step. The increment of the movement back and forth can of course be varied again, in order to avoid polymerization always being carried out over the same place on the vat bottom.
The lifting mechanism 64 is in turn provided with a force transducer 79 , the measured values of which are used by the control unit 61 in the way described above in connection with the first embodiment for limiting the force that is exerted on the build platform during the lowering and raising of the build platform.
Methods in which multiple different ceramic-filled photopolymerizable materials are used for building up the green blank may preferably also be used. This may take place, for example, by a plurality of vats being provided, each with an assigned reservoir with different materials. These vats may then be moved to the exposure unit and the build platform in the manner of a changeover carrier, in order to process different materials in a prescribed sequence. For this purpose, the multiple vats may, for example, be arranged in series one behind the other on a carrier, which is then linearly movable with respect to the exposure unit and the build platform, in order to provide a desired vat in each case. Alternatively, a plurality of rotatable vats, one of which is represented in FIGS. 1 and 2 , may be arranged on a circular ring of a larger plate, which for its part is in turn rotatable, in order in each case, by setting the rotational position of the plate, to bring a desired vat into the position between the exposure unit and the build platform in which the polymerization step of the respective layer is then carried out.
A special embodiment of a device with which various light-polymerizable materials can be used for building up an object is shown in FIG. 8 in a schematic plan view from above. Here there are four vats 104 on a turntable, arranged in the form of a circular ring. The arrangement of the feed device 108 , the further exposure unit 116 on a lifting mechanism 114 as well as the wiper 130 and the application device 126 lying in between is largely similar to the arrangement of the device from FIGS. 6 and 7 , with the exception of the fact that the components are not arranged along a linear path and the vat is not linearly movable, but instead the components are arranged along a segment of a circular ring and the vat correspondingly has the form of a segment of a circular ring. Between successive exposure steps in the same vat 104 , the vat is moved back and forth by an angle of approximately less than 90°, so that in turn a movement back and forth is obtained between the feed device 118 and the build platform located under the further exposure unit 108 .
If at a specific point in time one of the materials from one of the three other vats 104 is to be used, the turntable is turned by an angle corresponding to 90°, 180° or 270°, in order to bring one of the following vats to the device under consideration for building up the object.
As indicated at the bottom in FIG. 8 , a further device for building up objects, which can operate in parallel with the device shown at the top, may be provided on the turntable in the region of another segment of a circular ring.
Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without department from the spirit and scope of the invention as defined in the appended claims. | A method and a device for processing light-polymerizable material for the assembly of a mold, utilizing a lithography-based generative manufacturing technique wherein a layer of a light-polymerizable material, the material being located in at least one trough ( 4 ) having a particularly light-transmissive, horizontal bottom ( 6 ), is polymerized by illumination on at least one horizontal platform ( 12 ), the platform having a prespecified geometry and projecting into a trough ( 4 ), in an illumination field, wherein the platform ( 12 ) is displaced vertically to form a subsequent layer, light-polymerizable material is then added to the most recently formed layer, and repetition of the foregoing steps leads to the layered construction of the mold in the desired form, which arises from the succession of layer geometries. The invention is characterized in that the trough ( 4 ) can be shifted horizontally to a supply position, and the supply device ( 8 ) brings light-polymerizable material at least to an illumination field of the trough bottom ( 6 ), before the at least one trough ( 4 ) is shifted to an illumination position in which the illumination field is located below the platform ( 12 ) and above the illumination unit ( 10 ), and illumination is carried out. | 1 |
TECHNICAL FIELD
[0001] This invention relates generally to the field of building decoration materials technology, and more particularly to a building board and the method for manufacturing the same.
BACKGROUND OF THE INVENTION
[0002] A conventional building board, such as laminate flooring, comprises 2 or 3 wooden layers to make the flooring stable. For 3-layer wooden building boards, an outer layer is generally made of wooden material having certain wood grain patterns, and the surface thereof can be further coated with paints to improve the decorative effect; and an inner layer is normally made of wooden layers with plywood structure or other cheaper woods. The wooden layers of the inner layer provide effects of buffering and soundproofing, thus it further improves user experience.
[0003] However, in practical applications, the building board made of wooden layers is easy to corrode and deform after water ingress or wetting, or deform under humid conditions, and therefore the user experience is affected. Moreover, the manufacturing of wooden building board needs a huge amount of wood with high-energy consumption, which could severely destroy the natural environment.
SUMMARY OF THE INVENTION
[0004] There is a need to provide a building board that features erode proofing, free of deformation, and more environment-friendly.
[0005] Accordingly, in an embodiment of the present invention, a building board is provided, and the building board comprises a cement layer and a magnesium oxide layer.
[0006] Alternatively, the cement layer and the magnesium oxide layer are bound with glue.
[0007] Alternatively, the cement layer comprises cement and glass fiber.
[0008] Alternatively, the cement layer has a thickness from 2 to 20 millimeters.
[0009] Alternatively, the magnesium oxide layer has a thickness from 8 to 15 millimeters.
[0010] Alternatively, the cement layer has a density from 1.1 to 1.8 g/cm 3 .
[0011] In another embodiment of the present invention, a laminate flooring is provided. The laminate flooring comprises a cement layer and a magnesium oxide layer.
[0012] Alternatively, the laminate flooring further comprises a buffer layer, wherein the buffer layer is connected with the magnesium oxide layer.
[0013] Alternatively, the buffer layer comprises rubber or plastics.
[0014] Alternatively, the laminate flooring is shaped as square, rectangle, parallelogram, hexagon or octagon.
[0015] Alternatively, the laminate flooring is covered with a protective coating.
[0016] Alternatively, the protective coating is oil or varnish.
[0017] Alternatively, each side of the laminate flooring has tongue or groove to joint to each other, or has click system to joint to each other.
[0018] In a further embodiment of the present invention, a laminate door is provided. The laminate door comprises a cement layer and a magnesium oxide layer.
[0019] Alternatively, the laminate door further comprises a frame, wherein the frame is placed around the edge of the building board.
[0020] Alternatively, the frame comprises metal, wood or plastics.
[0021] In a further embodiment of the present invention, a laminate flooring is provided. The laminate flooring comprises cement layer and wooden layer.
[0022] In a further embodiment of the present invention, a method for manufacturing the building board provided. The method comprises the steps of: providing a cement board and a magnesium oxide board; dehydrating the cement board and the magnesium oxide board; and binding the cement board and the magnesium oxide board.
[0023] The building board of the present invention utilizes cement layer as the surface, which significantly improves its duration. The building board of the present invention has features of moisture proofing, mould and fungus proofing, erode proofing, fireproofing, soundproofing and free of deformation. Moreover, since the use of wood can be reduced, the building board of the present invention reduces the influence to the natural environment effectively.
[0024] Furthermore, the use of magnesium oxide board further improves the performance of the building board. Compared with the conventional wooden building boards, the building board of the present invention has better flexibility, and easier to cut.
[0025] These and other features of the present invention will be elucidated in the following embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Features, objects and advantages of the present invention can be easily understood with the reference to detailed description of the non-limiting embodiments taken in conjunction with the accompanying drawings, in which:
[0027] FIG. 1 illustrates a cross section view of a building board according to an embodiment of the present invention;
[0028] FIG. 2 illustrates a cross section of a building board according to another embodiment of the present invention;
[0029] FIG. 3 illustrates an overview of a laminate flooring according to a further embodiment of the present invention;
[0030] FIG. 4 illustrates a laminate door according to a further embodiment of the present invention;
[0031] FIG. 5 illustrates a flowchart of a method for manufacturing the building board according to an embodiment of the present invention;
[0032] FIG. 6 illustrates a cross section of a laminate flooring according to a further embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0033] The embodiments of the present invention are discussed in details below with reference to the accompanying drawings.
[0034] FIG. 1 illustrates a cross section view of a building board according to an embodiment of the present invention. The building board comprises a cement layer 102 and a magnesium oxide layer 104 . In practical applications, the building board can be used as laminate flooring, or laminate door of kitchen, cupboard and the like.
[0035] When the building board is installed on the ground as laminate flooring, the magnesium oxide layer 104 is positioned close to the ground, for example, on a cement floor or brick floor, and the cement layer 102 is positioned away from the ground. Therefore, with reference to the ground, the building board comprises the cement layer 102 and the magnesium oxide layer 104 in a top-down order. In an embodiment, the cement layer 102 and the magnesium oxide 104 are bound together with glue.
[0036] Compared with the wooden inner layer of the conventional wooden building boards, the magnesium oxide layer 104 of the building board of the present invention has better flexibility. The magnesium oxide layer 104 has features of nice moisture proofing, mould and fungus proofing, erode proofing, fireproofing, and free of deformation. Moreover, the magnesium oxide layer 104 also has the feature of soundproofing, and therefore the overall soundproof ability of the building board is improved. Thus, this building board is suitable for flooring pavement in storied buildings, or building doors such as kitchen door and the like.
[0037] The cement layer 102 of the building board may comprise cement and glass fiber. The density of the cement layer 102 can be precisely controlled by adjusting the composition of the cement and glass fiber. In an embodiment, the cement layer 102 has a density of 1.1 to 1.8 g/cm 3 . Furthermore, since the cement layer 102 has a hard surface and is not easy to wear out, and it also has features of nice moisture proofing, mould and fungus proofing, erode proofing, fireproofing, and free of deformation, and therefore the building board of the present invention is more durable compared with conventional building boards using wooden material.
[0038] In practical applications, the capability of moisture proofing and anti-deformation of the building board changes with the thickness of the cement layer 102 and the magnesium oxide layer 104 . In a specific embodiment, the cement layer 102 has a thickness from 2 to 20 millimeters. In another embodiment, the magnesium oxide layer 104 has a thickness from 8 to 15 millimeters. Such configuration in thickness ensures that the building board has perfect performance of anti-deformation and soundproofing. Moreover, since wood which is currently used with huge consumption has been substituted by the cement layer 102 and the magnesium oxide layer 104 , the building board of the present invention reduces the influence on the natural environment with cheaper manufacturing costs.
[0039] Preferably, the building board of the present invention can further comprise a heating device. For example, the heating device is configured outside the magnesium oxide 104 . Since heat coming from the heating device can spread easily and fast through the magnesium oxide layer 104 and up into the room, and the magnesium oxide layer 104 can also keep warm longer, the magnesium oxide layer 104 is better for floor heating
[0040] FIG. 2 illustrates a cross section view of a building board according to another embodiment of the present invention. The building board comprises a cement layer 202 , a magnesium oxide layer 204 and a buffer layer 206 , wherein the buffer layer 206 is connected to the magnesium oxide layer 204 .
[0041] In an embodiment, the buffer layer 206 comprises plastics or rubber, therefore the laminate floor is elastic and comfortable for walking on. Moreover, the buffer layer 206 makes the magnesium oxide layer 204 of the building board perfectly fit to the installing surface, such as the ground, and therefore the soundproofing performance of the building board is significantly improved.
[0042] FIG. 3 illustrates a top view of a laminate flooring according to a further embodiment of the present invention. As described in FIG. 3 , the laminate flooring is shaped as regular hexagon. In other embodiments, the laminate flooring can also be shaped as square, rectangle, parallelogram, octagon and so on.
[0043] In practical applications, different pieces of laminate flooring can joint together. In an embodiment, each side of the laminate flooring may have a connecting structure such as tongue or groove to joint to each other. In other embodiments, the laminate flooring can have click system to joint to each other, such as single click system or double click system. In a preferred embodiment, the surface of the laminate flooring is covered with a protective coating such as varnish or oil, which can ease the connection and provide further protection to the laminate flooring. In some embodiments, the oil used as the protective coating comprises natural oil or mineral oil. In practical applications, the oil coated on the surface of the laminate flooring may at least partially permeate into the surface of the laminate flooring and mix with the cement or other materials in the laminate flooring. The mixing of the oil and the cement flooring forms a specific surface, which is much stronger and more resistant to chemicals and physical scratches.
[0044] It should be understood that the present invention is not limited to the connection manner between different pieces of the laminate flooring.
[0045] FIG. 4 illustrates a laminate door according to a further embodiment of the present invention. The laminate door can be used as kitchen door, cupboard door and the like. The laminate door comprises the building board illustrated in FIG. 1 or 2 .
[0046] In FIG. 4 , the laminate door further comprises a frame 408 , which is placed around the edge of the building board. Optionally, the frame 408 can comprise metal, wood or plastics.
[0047] In some other examples, the building board depicted in FIG. 1 may also be used for lampshades or housings for receiving lamps. The lampshades or housings may have openings for leaking light out. As the building board of the present invention has features of erode proofing, fireproofing and free of deformation, the lampshades or housings made of the building board is more durable. It should be understood that the previous embodiments for applying the building board of the present invention are merely illustrative and are not limited.
[0048] FIG. 5 illustrates a flowchart of a method for manufacturing the building board according to an embodiment of the present invention.
[0049] In step S 502 , provides a cement board and a magnesium oxide board.
[0050] Specifically, the cement board can be made from cement and glass fibers mixed in a predetermined ratio. The magnesium oxide board can be made from magnesium oxide powder, glass fibers and/or wooden fibers mixed in a predetermined ratio.
[0051] In step S 504 , dehydrates the cement board and the magnesium oxide board.
[0052] Specifically, the cement board and the magnesium oxide board can be kept in a balance room, where the temperature and the humidity can be precisely controlled. In an embodiment, the magnesium oxide board and the cement board can be kept in the balance room for 2-3 weeks, so as to lower the water in the cement board and the magnesium oxide board down to 10-15% by mass.
[0053] In step S 506 , binds the cement board and the magnesium oxide board.
[0054] In an embodiment, step S 506 further comprises binding the cement board and the magnesium oxide board by cold pressing. The process time of the cold pressing is 6 to 10 hours, and the pressure is 5 kg/cm 2 . Optionally, the cement board and the magnesium oxide board can be bound with WBP (Water Boiled Proof) glue such as melamine glue and phenolic aldehyde glue. WBP glue has features of water proofing and water boiled proofing, which can effectively ensure the binding of the cement board and the magnesium oxide board.
[0055] In an embodiment, after step S 506 , the method further comprises binding buffer material to the magnesium oxide board. That is, the buffer material adheres to the side of the magnesium oxide board far away from the cement board. Further, the buffer material can be bound to the magnesium oxide board with WBP glue. Optionally, the buffer material can be plastics or rubber.
[0056] In an embodiment, after step S 506 or the step of binding buffer material, the method further comprises cutting the bound cement board and magnesium oxide board. Based on different applications, the building board can be separated as different sizes.
[0057] In an embodiment, after the step of cutting the building board, the method further comprises forming a tongue or groove at each side of the building board, or forming a click system at each side of the building board.
[0058] In an embodiment, after the step of cutting the building board, the method further comprises coating a protective coating over the cement board, such as oil, varnish or other comparable materials. Optionally, coloring materials can be added into the protective coating so as to improve the decorative effect of the building board.
[0059] FIG. 6 illustrates a cross section of a laminate flooring according to a further embodiment of the present invention. As shown in FIG. 6 , the laminate flooring comprises cement layer 602 and wooden layer 604 . When the laminate flooring is installed on the ground, the wooden layer 604 is positioned close to the ground, for example, on a cement floor or brick floor, and the cement layer 602 is positioned away from the ground. Therefore, with reference to the ground, the laminate flooring comprises the cement layer 602 and the wooden layer 604 in a top-down order.
[0060] In an embodiment, the cement layer 602 and the wooden layer 604 are bound together with glue. Optionally, the cement layer 602 and the wooden layer 604 can be bounded with WBP (Water Boiled Proof) glue, such as melamine glue and phenolic aldehyde glue. The WBP glue has features of water proofing and water boiled proofing, which can ensure the binding of the cement layer 602 and the wooden layer 604 .
[0061] The cement layer 602 of the laminate flooring may comprise cement and glass fibers. The density of the cement layer 602 can be precisely controlled by adjusting the composition of the cement and the glass fiber. In an embodiment, the cement layer 602 has a density of 1.1 to 1.8 g/cm 3 . Alternatively, the cement layer 602 has a thickness from 2 to 20 millimeters. The cement layer 602 features moisture proofing, mould and fungus proofing, erode proofing, fire proofing, and free of deformation.
[0062] In an embodiment, the laminate flooring further comprises a butter layer which is connected to the wooden layer 604 . Specifically, the buffer layer is connected to one side of the wooden layer 604 far away from the cement layer 602 . The buffer layer comprises rubber or plastics materials, which has good elasticity, and therefore the laminate flooring has better performance on sound proofing.
[0063] In an embodiment, the laminate flooring can be covered with protective coating, for example, oil or varnish, so as to protect the cement layer 602 .
[0064] In an embodiment, the laminate flooring can be shaped as square, rectangle, parallelogram, hexagon, octagon and so on, and each side of the laminate flooring can have a connecting structure such as tongue or groove for the ease of connection. In another embodiment, the laminate flooring can use click systems to joint to each other, such as single click system or double click system. It should be understood that the present invention is not limited to the connection manner.
[0065] Although the present invention has been described above in the accompanying drawings and detailed descriptions, it should be understood that such descriptions are merely illustrative and are not limited; the present invention is not limited to such embodiments. Those skilled in this art may understand and implement other variations from the disclosed embodiments by studying the specification, disclosed contents, accompanying drawings and appended claims. | Building boards and method for manufacturing the same are provided. The building board comprises a cement layer ( 102 ) and a magnesium oxide layer ( 104 ). The method for manufacturing the building board comprises the steps of providing a cement board and a magnesium oxide board, dehydrating and binding the cement board and the magnesium oxide board. The performance of moisture proofing, fungus proofing, erode proofing, fireproof and others can be improved by utilizing the building boards. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of PPA application No. 61/992,058, filed May 12, 2014 by the present inventor, which is incorporated by reference.
FEDERALLY SPONSORED RESEARCH
[0002] None; no federally sponsored research was involved in this invention
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] None; no joint research agreement associated with this invention
SEQUENCE LISTING
[0004] None and not applicable to this invention
STATEMENT REGARDING PRIOR DISCLOSURES BY AN INVENTOR OR JOINT INVENTOR
[0005] Not applicable (i.e. no disclosures by inventor prior to PPA No. 61/992,058)
BACKGROUND OF INVENTION
[0006] Previously, numerous devices for positioning, securing, and otherwise hanging items to a vertical or near vertical surface, typically a wall, are known in the prior art. Many efforts have been made to solve the several problems that exist when attempting to “hang something on a wall,” an often frustrating, time consuming, and surprisingly difficult task.
[0007] These problems include, but are not limited to: a) easily attaching the item to the surface via a hanger—without the need to “look behind the item or picture” in order to avoid snagging on the nail or fastener used to attach a given hanger or hook to the surface (the “don't miss the hook, and don't snag the nail either” dilemma), b) positioning the item close to where you want it visually—without the need to remove and reattach the hanger, c) maintaining the item hung to the surface in a level and pleasing position (e.g. no canting, slanting, etc.) despite occasional disruptive vibrations to the surrounding environment or in the case of imperfect placement of a picture mount or clip used in conjunction with a hanger (e.g. placement of the mount slightly off-center of the item hung or otherwise attached to the vertical surface), d) preventing unintentional disconnect from the hanger as a result of shaking, bumping, or jarring events (e.g. minor earthquake, people or objects bumping into the item hung on the surface, etc.).
[0008] A large commercial market exists for picture hooks, hanger systems, and other hanger devices. Solving the problems of what would seem to be a simple task has been a focus of several devices available on the market today.
BRIEF SUMMARY OF THE INVENTION
[0009] Solving the problems associated with “hanging something on a wall” is accomplished significantly by providing a hanger hook (open on both ends) that includes an internal compression force element that applies pressure in a mostly orthogonal direction to the force of gravity and increases stabilizing frictional forces that are on vertical interior surfaces (opposing to the compression force element surface) of the hanger hook. This hanger hook, among other benefits, helps stabilize, prevent or limit canting due to disturbing effects of minor forces in the surrounding environment that lead to misaligned pictures and items hung on or attached to a wall or vertical surface, and prevent unintentional disconnect.
[0010] The hanger hook includes effectively recessed fastener positions as to eliminate snagging, or otherwise mistakenly hanging an item on the nail (or other type of fastener used to secure a hanger or picture hook to a vertical surface) or an inappropriate part of a picture hanger hook. The recessed fastener aspect of the hanger hook eliminates the need to “look/reach behind the object” in order to make certain that the hanger hook has been properly engaged. Some embodiments are envisioned to employ a “click” sound to indicate proper engagement of the hanger hook.
[0011] Easy removal of the item from the hanger hook is accomplished by reversing the compression force via the application of a pushing action near the hanger hook and typically toward the wall or vertical surface effectively releasing the item engaged in the hanger hook from frictional surfaces that contact the vertical interior surface of the hanger hook and then moving the item vertically or horizontally or combination of each direction sufficient to clear the hanger hook. Removal (as in engagement of the hanger hook) is accomplished without the need to look behind the picture or other type of item that is hung to a vertical or near vertical surface. Similarly, repositioning of the item being hung can be adjusted vertically or horizontally (to the limit of the physical constraints of the hanger hook) by countering the compressive force, moving the item the desired distance, then releasing and thereby engaging or allowing the compressive force to once again become effective.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In accordance with one embodiment FIG. 1 illustrates the hanger hook with hanger hook frame (wall leg) 10 a - 1 , hanger hook frame (base) 10 b - 1 , hanger hook frame (opposing leg) 10 c - 1 , hanger hook pocket 12 - 1 , compression element 14 - 1 , compression element contact surface 15 - 1 , friction element 16 - 1 , recessed fastener holes 18 - 1 . Compression element 14 - 1 illustrates of the use of materials that can be attached to the side leg 10 a - 1 forming hanger hook pocket 12 - 1 opposite to friction element 16 - 1 . Materials chosen in this embodiment should provide the necessary elastic, compressible characteristics needed to provide sufficient orthogonal force against the hook frame (opposing leg) 10 c - 1 in order to secure an item inserted into hook pocket 12 - 1 .
[0013] In accordance with another embodiment FIG. 2 illustrates the hanger hook with hanger hook frame (wall leg) 10 a - 2 , hanger hook frame (base) 10 b - 2 , hanger hook frame (opposing leg) 10 c - 2 , hanger hook pocket 12 - 2 , compression element 14 - 2 , friction element 16 - 2 , recessed fastener holes 18 - 2 . Compression element 14 - 2 is shown as a pair of “arms” that extend into hanger hook pocket 12 - 2 to depict how flexible, elastic (and providing sufficient compressible force) arms can act as source of the compression force needed to create the benefits of this hanger hook.
[0014] FIG. 3 illustrates how an embodiment depicted might be employed using a matching or tuned “male” mounting clip 20 - 3 . Mounting clip 20 - 3 is shown to fit suitably into the hanger hook pocket 12 - 3 . It can be seen from FIG. 3 how a matched mounting clip and hanger hook can be engaged.
DETAILED DESCRIPTION OF THE INVENTION
[0015] According to this invention, a hanger hook is provided with open sides, a vertical surface contacting hanger frame leg (e.g. 10 a - 1 ), an opposing hanger frame leg (e.g. 10 c - 1 ), and a connecting hanger frame base (e.g. 10 b - 1 ). Combining the hanger hook legs results in a hanger hook pocket (e.g. 12 - 1 ) that has generally right angle construction with a flat base. This generally flat base for the hanger hook pocket provides several benefits: (a) distribution of downward pressure, (b) the necessary space for compression element design and action, (c) opportunity for a customer to make subtle additions to the base and thereby raise an item being hung by the hanger hook without introducing destabilization.
[0016] The hanger hook may be attached (e.g. nailed, screwed, or by the use of similar means) to a vertical surface utilizing the recessed fastener holes (e.g. 18 - 1 , 18 - 2 , 18 - 3 ). The hanger hook can have as few as one fastener hole though embodiments using more fastener holes are envisioned that would allow easier leveling of hanger hook. The sloping face (illustrated in FIG. 1 ) combined with recessed fastener holes guides an appropriately sized mounting clip smoothly and directly into the hanger hook pocket 12 - 1 . It is envisioned that any appropriately sized mounting clip that is secured to the back of an item, such as a picture frame, to be hung on a wall or otherwise vertical surface would engage the hanger hook. The reader can see from FIG. 3 how the hanger hook is engaged: mounting clip 20 - 3 slides over a recessed fastener, compresses the compression element, and then is in the hanger hook pocket 12 - 3 ; releasing and engaging the compression force secures the clip against the vertical, inside friction element 16 - 3 on the opposing leg of the hanger hook frame 10 c - 3 thereby securing the item to be hung on a wall or vertical surface. Additionally, an embodiment illustrated in FIG. 1 depicts where the surface of the compression element can be coated with a friction-lowering compound or material (compression element contact surface 15 - 1 ). Reducing friction associated with the surface of the compression element (and focusing friction benefits to the outer, opposing hanger hook leg) can be advantageous in certain product designs for the market.
[0017] The hanger hook frame can be made out of many materials depending upon strength requirements or marketing needs for the product. These materials include, but are not limited to, metals, plastics, and composite materials. The hanger hook compression element can easily be made from a diverse set of materials known in the art—including, but not limited to, elastic metals and alloys, polymers with elastic characteristics, composite materials with elastic characteristics, springs, and opposing magnetic pole surfaces.
[0018] The hanger hook friction element (e.g. 16 - 1 ) provides many benefits, particularly when combined with the compression force applied via the compression element. FIG. 2 and FIG. 3 illustrate one embodiment that employs a frictional surface on both a “male mounting clip” and the interior vertical surface of the hook frame (opposing leg) (e.g. 10 c - 3 ). The friction element provides functional and improved stability, both laterally and vertically, to the hanger hook described here, improving on existing picture hook designs available in the market today. The friction element can be manufactured from many materials known in the art today—including but not limited to crystals or crystalline-like materials (e.g. “sandpaper”), metals, rubber and other rubber-like materials, polymers with high friction coefficients, solid or soft materials shaped in configurations to create frictional surfaces.
[0019] The reader can see accordingly, from the few embodiments described here, that the hanger hook provides many improvements and superior benefits over existing picture hanging options available today including: a) ease of engagement of a mounting clip or wire into the hanger hook, b) adjustability both laterally and vertically—a much valued benefit when arranging items on a wall for display, c) superior stability—by using orthogonal forces and added friction resulting from the employment of the interior compression force, and d) superior engagement or attachment of a mounting clip or device (attached to a picture or item to be hung on a wall) to the hanger hook by utilizing additional forces beyond that of gravity.
[0020] While the above description contains many specifications, these should not be construed as limitations on the scope of any embodiment, but as exemplifications of various embodiments thereof. Many other ramifications and variations are possible with in the teachings of the various embodiments. Thus, the scope should be determined by the appended claims and their legal equivalents, and not by the examples given. | An object hanger hook for hanging an item, such as a picture, to a vertical or near vertical wall surface utilizing elements that provide internal, generally orthogonal forces against an opposing internal hook surface that help secure and level item to be hung. Embodiments are described each showing force elements and elements to make engagement or release of object hanger hook from item to be hung easy and adjustable. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a dirt remover suitable for the removal of dirt floating, suspended or settling in water tanks such as swimming pools and water storage tanks.
Large water tanks such as swimming pools and water storage tanks which are generally installed outdoors are in most cases left uncovered because of their particular uses and their invevitable possession of large openings. Thus, they have the disadvantage that falling leaves and various forms of dirt drift into the tanks and pollute the water held therein. Particularly in the case of swimming pools, hair from swimmers, loose threads from swimmers' suits and the like frequently pollute the water held therein.
Because of such pollution, swimming pools and water storage tanks which are required to retain the quality of their water above a fixed level are provided with means of purification capable of cyclically filtering water to remove dirt together with defiling matter. The dirt of light weight which floats on the water surface and the dirt of heavy weight which settles to the water bottom fail to mingle into the circular flow of water and defy effective removal by such means as are adapted to remove the dirt from the water being circulated therethrough. For this reason, there has been often followed a practice of scooping the dirt in the water tank with a bag-shaped net attached to the leading end of a handle. Conventional scooping devices of this kind have a circular frame attached to the end of a handle and a net hung from the frame. They are, accordingly, capable of removing the dirt floating on the water surface or suspended in the water but are unsuitable for scooping the dirt settling to the bottom of the water tank. Particularly the dirt consisting of fine particles such as hair from human bodies and loose threads from suits which occur in swimming pools and the dirt of high specific gravity consisting of pebbles and broken iron pieces are considered hardly capable of being scooped by such conventional means.
This invention relates to a dirt remover developed in a view of such true state of affairs. An object of the invention is to provide a dirt remover adapted so as to permit ready removal of not only the dirt floating on the water surface and suspended in the water but also the dirt settling to the water bottom in water tanks. Another object of the present invention is to provide a dirt remover capable of safely scooping the dirt settling to the tank bottom without scratching the paint applied to coat the bottom or inflicting any injury to the bottom surface.
SUMMARY OF THE INVENTION
To accomplish the objects described above according to the present invention, there is provided a dirt remover which uses a straight frontal edge member in the forward part of a frame attached to the leading end of a handle and, moreover, attaches to the frontal edge member a plate-shaped sliding piece made of a material such as foamed polyethylene excelling in resistance to water and possessing proper degrees of rigidity and elasticity, so that the sliding piece prevents the leading end of the frame from coming into direct contact with the tank bottom and, when slid on the tank bottom, scrapes up the settling dirt and conveys it backwardly into a net having the edges thereof fastened to the inner sides of the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the dirt remover of this invention for use with a water tank, with part of the handle thereof cut away for convenience of illustration.
FIG. 2 is an exploded perspective view of the dirt remover of the present invention for use with a water tank.
FIG. 3 is an enlarged sectioned view of part of the dirt remover taken along the line III--III of FIG. 1.
FIG. 4 is an enlarged sectioned view of part of the dirt remover taken along the line IV--IV of FIG. 1.
FIG. 5 is an exploded perspective view illustrating other preferred embodiments of the frontal frame member and lateral frame members of the dirt remover according to the present invention.
FIG. 6 is a longitudinal cross section of a portion of the elements of FIG. 5 in their assembled state.
Now, the present invention will be described hereinbelow with reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
In the acccompanying drawings, the handle with which the dirt remover of this invention is operated is denoted by symbol 1, the scooping portion attached to the leading end of the handle by symbol 2 and the sliding piece provided along the frontal edge of the scooping portion by symbol 3. The scooping portion 2 mentioned above is composed of a frame 4 and a net 5 hung from the inner sides of the frame 4, and the frame 4 is composed of a rear frame member 6, lateral frame members (left and right) 7, 8 and a frontal frame member 9.
In the present preferred embodiment, the frame 4 is formed in a rectangular shape by bending a bar-shaped strip of aluminum in the shape of three sides of a rectangle for thereby forming the rear frame member 6 in the middle and the two lateral frame members 7, 8 of an equal length perpendicularly extended from the rear frame member 6, fastening connecting members 10, 10 of a plastic material to the leading ends of the lateral frame members 7, 8 and setting the frontal frame member 9 made of a bar-shaped strip of aluminum in position between the connecting members.
The connecting members 10, 10 mainly serve the purpose of connecting the lateral frame members 7, 8 with the frontal frame member 9. They are each possessed of a first insertion hole 11a opening to the rear side for admitting the leading end of the relevant lateral frame member and a second insertion hole 11b formed perpendicularly relative to the first insertion hole and opening laterally towards the center of the frontal frame member. Attachment of the connecting members to the lateral frame members 7, 8, therefore, can be accomplished by inserting the leading end of the lateral frame member 7 into the insertion hole 11a of one of the connecting members 10 and the leading end of the lateral frame member 8 into the insertion hole 11a of the other connecting member 10. Then the opposite ends of the frontal frame member 9 are inserted into the second insertion holes 11b, 11b which have been opposed to each other in consequence of the attachment mentioned above. As the result, the frontal frame member 9 and the lateral frame members 7, 8 are connected, completing the frame 4 in a firmly closed rectangular shape. To be more specific, in the aforementioned connecting members 10, 10 of the present preferred embodiment, the first insertion holes 11a, 11a are each formed in the shape of a rectangualr parallellepiped with a vertically oblong inner cross section substantially conforming to the outer cross section of the lateral frame members 7, 8 and the second insertion holes 11b, 11b are each formed in the shape of a rectangular parallellepiped with a horizontally oblong inner cross section such that, when the connecting members are joined with the frontal frame member 9, the major faces of the frontal frame member extend perpendicularly to the holes 11a, 11b are slightly smaller than the outer cross section at the leading ends of the corresponding frame members so that the mutual connection between the frame members can be effected by having the leading ends of the frame members forcibly inserted into the insertion holes. In addition, the connecting members 10, 10 are each provided integrally on the upper sides thereof with protuberances 12, 12 adapted to withstand percussions exerted upon the connecting members to facilitate the aforementioned insertion. The protuberances will be further discussed below.
In the case of the present preferred embodiment, because of the construction of the frame 4 formed as described above, attachment of the net 5 to the inner sides of the frame is accomplished by first having the corresponding three sides of the rectangular periphery of the net attached to the rear frame member 6 and the lateral frame members 7, 8 before the connection of the frontal frame member 9, and thereafter fastening the remaining side of the net to the frontal frame member 9.
The net 5 illustrated herein is a synthetic fiber net formed by interweaving filaments such as of polyester or polyethylene in a relatively small mesh size with a view to offering resistance to water and ensuring rapid drainage of water during use. This net is cut in an area somewhat larger than the inner area of the aforementioned frame 4. The three sides of the net along the rear edge and the lateral edges are each folded back to form a cylindrical pouch, so that the attachment of these sides of the net to the rear frame member 6 and the lateral frame members 7, 8 which have been formed integrally by bending one bar-shaped strip of aluminum will be accomplished by inserting the three sides of the frame 4 through the cylindrical pouches of the net. Of course, in this case, the net 5 hangs loosely from the frame because it has been cut in a somewhat larger area than the inner area of the frame as described above. After the net has been attached to the rear frame member 6 and the lateral frame members 7, 8 in the manner described above, the frame 4 is completed by setting the frontal frame member 9 in position between the leading ends of the lateral frame members through the medium of connecting members 10, 10. In the present preferred embodiment, the scooping portion 2 is completed and, at the same time, the sliding piece 3 is set in position by having the front edge of the aforementioned net 5 spread on the upper face of the frontal frame member 9, the aforementioned sliding piece placed on top of the front edge of the net and an auxiliary frontal frame member 13 mounted on the sliding piece and thereby allowing the front edge of the net 5 and the sliding piece 3 to be positioned between the frontal frame member 9 and the auxiliary frontal frame 13 and thereafter having plastic rivets 14 driven through the four layers at points spaced suitably in the longitudinal direction for thereby uniting the four layers into one tight assembly. (See FIGS. 2, 3 and 4.)
In this case, to ensure effective driving of the rivets 14, holes 9a, 13a, 5a and 3a for permitting passage of the rivets are perforated at the corresponding positions in the frontal frame member 9, the auxiliary frontal frame member 13, those in the net 5 and the sliding piece 3. The rivets 14 to be used herein are those of the type possessing heads at the rear ends of their shanks and arrow-shaped engaging hooks at the forward ends thereof. After the four layers have been piled up as described above, these rivets are pushed into the holes 9a of the frontal frame member, through the intervening holes 3a, 5a and out of the uppermost holes 13a of the auxiliary frontal frame member 13 until the engaging hooks at the leading ends of the rivet shanks emerge from the auxiliary frontal frame member 13. The assembly of the four layers is completed by radially spreading the engaging hooks into tight engagement with the upper surface of the frame member 13.
In the preferred embodiment, the tight union of the frontal frame member 9 and the auxiliary frontal frame member 13 has been described as being attained by use of plastic rivets. It is, of course, possible to accomplish this union by using rivets of metal material or small bolts and nuts.
FIG. 5 and FIG. 6 represent other preferred embodiments of the method of connection between the lateral frame members 7 (or 8) and the frontal frame member 9 described above. In FIGS. 5 and 6 , 30 denotes one of the two lateral frame members forming a part of the frame 4, 31 a frontal frame member, 32 a connecting member, 33 an auxiliary frontal frame member, 34 a net to be hung from the inner sides of the frame, 35 a sliding piece, and 36 a rivet. Comparison of the second preferred embodiment with the first preferred embodiment described above reveals the differences in that the insertion holes 32a and 32b which are formed in each connecting member 32 internally communicate with each other, that each lateral frame member has a notch 37 formed in one lateral edge close to the forward end thereof and the frontal frame member 31 has a projection 38 formed on the leading end thereof, and that one of the rivets designed to provide tight union of the frontal frame member 31 and the auxiliary front frame member 33 is driven through the aforementioned connecting member.
In the connecting member 32 which is used in the present preferred embodiment, a first insertion hole 32a for permitting the insertion of the lateral frame member 30 and a second insertion hole 32b for permitting the insertion of the frontal frame member 31 in a direction perpendicular to the insertion hole 32a are formed with the inner end of the second insertion hole 32b piercing through the lateral side of the insertion hole 32a for mutual communication, so that safe connection between the frontal frame member 31 and the lateral frame member is accomplished by first inserting the lateral frame member into the first insertion hole 32a, then inserting the frontal frame member 31 through the second insertion hole 32b until the leading end thereof collides into the lateral side of the lateral frame member 30 and thereafter bringing the projection 38 formed at the leading end into fast engagement with the notch 37 formed in the lateral frame member for thereby precluding easy separation of the lateral frame member from the connecting member. Moreover, the connecting member 32 has a through hole 39 vertically perforated in the portion for admitting the frontal frame member and the frontal frame member similarly has a through hole 31a vertically perforated at a corresponding position so that one rivet 36 driven through the registered holes 39 and 31a will prevent the frontal frame member from easily separating from the connecting member. Similarly to the foregoing preferred embodiment, the rivet is passed through the hole 34a perforated in the net 34, the hole 35a perforated in the sliding piece 35 and the hole 33a perforated in the auxiliary frontal frame member 33 to provide tight union of the frontal frame member 31 and the auxiliary frame member 33, with the net 34 and the sliding piece 35 immovably interposed therebetween.
In short, unlike the first preferred embodiment wherein the connection of the lateral frame member 7 (or 8) with the frontal frame member 9 is accomplished simply by forcibly inserting the leading ends of these frame members into the corresponding insertion holes of the connecting member 10, the second preferred embodiment enhances the safety of the connection by causing the lateral frame member 30 and the frontal frame member 31 to be engaged with each other inside the connecting member and further securing the frontal frame member 31 to the connecting member by insertion of the rivet 36 through the frontal frame member, whereby the lateral frame member 30 and the frontal frame member 31 will not readily separate themselves from the connecting member.
The sliding piece 3 which is held fast in position by the aforementioned tight union of the frontal frame member 9 and the auxiliary frontal frame member 13 is formed of a material such as highly foamed polyethylene which excels in resistance to water and possesses proper degrees of rigidity and elasticity. This sliding piece is formed in the shape of a plate having a thickness sufficient to confer proper degrees of rigidity and elasticity to the sliding piece. The sliding piece is formed in the shape of a strip having a length substantially equal to the length of the frontal frame member 9 and a width greater than the width of the frontal frame member so that, when it is immovably fastened between the frontal frame member 9 and the auxiliary frontal frame member 13, one edge (frontal edge) 20 thereof will protrude from the frontal frame member 9 substantially throughout the entire length of the frame 4 and the entire length of the front edge of the scooping portion. In the present preferred embodiment, the frontal edge 20 of the sliding piece which protrudes as described above is cut aslant in the shape of an edge in a cutting blade in order that the sliding piece may come into tight contact with the bottom of the water tank.
The handle 1 is formed of a metal pipe. This handle 1 is attached to the frame 4 through the medium of a connecting member 15.
The connecting member 15 mentioned above is formed of a round bar of plastic material having a tapered peripheral surface. The connecting member is provided at the leading end thereof with a notch 16 of sufficient size to receive the rear frame member 6 of the frame 4. Attachment of this connecting member 15 to the frame is accomplished by setting the rear frame member in position within the notch 16 and inserting a screw 18 through a hole 17 perforated in advance in the rear frame member into a hole drilled in advance in the connecting member 15. The handle 1 has an internal thread 19 formed on the inner surface of the opening at the leading end thereof. The handle is then connected to the frame 4 by admitting the leading end of the connecting member 15 into the opening and turning the handle around its axis and thereby allowing the aforementioned internal thread 19 to bite into the tapered peripheral surface of the connecting member.
The dirt remover of the present invention is constructed as described above. For actual use of the dirt remover, the dirt such as fallen leaves floating on the water surface is scooped out in the net 5 hung from the inner sides of the frame 4 when the user holds the handle in such a way as to permit about half of the scooping portion 2 to dip into the water and then moves the scooping portion horizontally. The dirt suspended in the water can be scooped out when the user holds the handle in such a way as to keep the scooping portion completely immersed in the water and then moves the scooping portion horizontally in much the same way as above. The dirt settling to the bottom of the water tank can be scooped out when the user lowers the handle until the scooping portion is completely immersed in the water and the sliding piece 3 attached to the forward end of the frame 4 comes into contact with the bottom surface of the water tank and then moves the sliding piece 3 along the bottom surface. In this case, during the forward motion of the device, the scooping portion 2 is inclined backwardly so that the sliding piece 3 protruding from the frontal edge of the scooping portion is diagonally held in contact with the bottom surface of the water tank. When the scooping portion is moved in the manner described above, the dirt deposited on the bottom surface of the water tank is scraped up by the sliding portion, then guided along the inclined upper surface of the sliding piece, led into the net 5 hung inside the frame and collected therein. With the dirt remover of the present invention, removal of the dirt in the water tank involves a work process which comprises the steps of immersing the scooping portion in the water, moving the immersed scooping portion forward, lifting the scooping portion from the water and removing the collected dirt from the scooping portion. This unit work process is repeated until the interior of the water tank becomes sufficiently clean. In the work process described above, the removal of the collected dirt from the net is readily accomplished by turning the scooping portion 2 upside down and exerting a mild impact upon the scooping portion from behind. In this case, if the frame is struck directly against the floor surface, there is a possibility that the edge portion of the net hung from the frame will sustain cuts. To avoid this disadvantage, the present invention has the connecting members 10 each provided on the upper face thereof with a protuberance 12. Thus, the impact required for the removal of the collected dirt is obtained by striking these protuberances against the floor surface or some other suitable hard surface. While the scooping work is in progress, the scooping portion 2 should not be moved backwardly, for the backward movement of the scooping portion entails dispersion of the collected dirt in the water.
The present invention provides effective removal of the dirt floating on the water surface and the dirt suspended in the water as well as the dirt settling to the bottom of the water as described above. Thus, the dirt remover of this invention can be advantageously used for the removal of dirt from water tanks such as swimming pools.
Particularly when the dirt remover of this invention is used for the removal of dirt settling to the bottom of a water tank, the sliding piece protruding from the leading end of the scooping portion has its leading edge brought into intimate contact with the bottom surface of the water tank by virtue of the elasticity of the material of which the sliding piece is made. The intimate contact enables the sliding piece to scoop up even small iron pieces. Because the sliding piece possesses the flexibility originating in its material, the sliding contact of this sliding piece with the bottom surface will not inflict any damage to the bottom surface. Thus, the dirt remover has the advantage of offering safety of use. | A dirt remover for a water tank, which can readily remove not only the dirt floating on the water surface and the dirt suspended in the water but also the dirt settling to the tank bottom without inflicting any injury on the bottom surface of the tank, includes a frame formed of a rear frame member, two lateral frame members extending forward from the opposite ends of the rear frame member, and a frontal frame member set in position straight between the leading ends of the two lateral frame members. A net is hung from the inner sides of the frame loosely enough for the middle portion thereof to sag down, the net forming a scooping portion in conjunction with the frame. A handle has a leading end thereof attached to the rear frame member of the frame, the handle serving for the operation of the scooping portion. A plate-shaped sliding piece made of a material possessing proper degrees of rigidity and elasticity is fastened to the frontal frame member of the frame throughout the entire length thereof in such a way that the leading end of the sliding piece will protrude from the scooping portion. | 4 |
FIELD OF THE INVENTION
The present invention relates generally to the installation of single passenger interface unit on the floor area of an aircraft, and more particularly, to the installation of a single passenger interface unit on the floor area of an aircraft that is able to be easily relocated to a.different area inside the aircraft.
BACKGROUND OF THE INVENTION
With the advent of the telecommunications and the computer age, individuals are constantly in need of electronic contact with external sources such as telecommunications networks and the internet. This direction is exemplified by the increase and advancement in wireless technology including cell phones, wireless LANs and wireless modems. Such wireless technology allows individuals to communicate with other individuals and connect to computer networks and the internet from remote areas such as inside automobiles, camp sites, and vacation resorts. As a result, individuals are able to perform their jobs and maintain communication while traveling and at locations far outside the office, thereby transforming the traditional brick and mortar office environment into a virtual office space.
While wireless technology is heavily used in land based locations such as land vehicles, it has not as-of-yet found widespread use in certain types of transportation. Specifically, the use of wireless technology on aircrafts has not been penetrated due to the great distance between the remote computer or cellular device and the cellular hub as well as the restrictions placed upon passengers due to potential interference of the transmitting cellular device with the aircraft's navigation, systems. To overcome this, some aircraft manufacturers have provided a single wireless link to allow passengers in the aircraft to connect to a ground based cellular link.for connection to a cellular or computer network. While this technological advancement serves to provide adequate transmission power to reach ground based connections and does not interfere with the aircraft's navigational systems, the logistics of properly connecting to a passenger's individual computer still remains to be achieved and refined.
Specifically, network servers or passenger interface units are required to be installed in the aircraft. Each passenger interface unit provides connections for multiple computer users to connect. The passenger interface unit, in turn, communicates with a transmitter/receiver external to the aircraft for transmitting information to and from a ground based link. The passenger interface unit, which is bulky and fragile, must be mounted in a location out of sight and hindrance from the aircraft passengers. Typically, this location is in the side walls of the aircraft. The.passenger interface unit is placed through a hole in the side wall and mounted to the frame of the aircraft. The hole is then sealed back up while allowing for a small aperture to pass communications cable to each of a plurality of passenger seats. While this mounting method does serve to adequately mount the passenger interface unit, some drawbacks exist. Specifically, this mounting method requires the presence of large apertures for communication cable to pass through, resulting in an aesthetically unpleasing surface. Moreover, after the passenger interface unit is removed, there remains a hole which must somehow be re-sealed. The present invention was developed in light of these and other drawbacks.
SUMMARY OF THE INVENTION
To overcome these and other drawbacks, the present invention provides a passenger interface unit that includes a server having an attachment means for attaching to a seat track in an aircraft. In another aspect an aircraft is provided having a passenger interface unit and a seat track. The passenger interface unit includes a server mounted to a support plate, where the support plate includes a pair of ears. The ears are attached to the seat track. Cables run from the server, along an area between the seat track and a seat.track cover until each respective cable terminates at a respective seat. Accordingly, the server provides independent computer connections to each respective seat in a block of seats. In another aspect, a plurality of passenger interface units is provided such that most or all of the seats throughout the aircraft are provided with computer connection.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and he accompanying drawings, wherein:
FIG. 1 is a perspective view of a passenger interface unit mounted to a floor of an aircraft according to the present invention.
FIG. 2 is a perspective view of a passenger interface unit mounted to a floor of an aircraft according to the present invention;
FIG. 3 is a plan view of a passenger interface unit mounted to a floor area of an aircraft according to the present invention;
FIG. 4 is a perspective, exploded view of the mounting structure of a passenger interface unit according to the present invention; and
FIG. 5 is a perspective exploded view of V in FIG. 4 of the mounting structure for mounting a passenger interface unit to an aircraft according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Referring now to FIGS. 1 and 2, the present invention is shown and described. Referring now to FIG. 1, a passenger interface unit 10 is shown positioned under an aircraft seat 12 . As will be described in greater detail, passenger interface unit 10 is secured to seat track 14 which also secures seat leg 16 of aircraft seat 12 to the floor area of an aircraft. As shown in FIG. 2, passenger interface unit 10 preferably is connected to the middle seat track 14 and extends traversely under each respective aircraft seat 12 . However, it is noted that passenger interface unit 10 can extend from any seat track used to secure aircraft seats 12 . In addition, passenger interface unit 10 can be positioned over seat track 14 or extending in any direction from seat track 14 .
As shown in FIG. 4, passenger interface unit 10 includes a server 18 mounted to a support plate 20 . Server 18 is a computer server having a plurality of I.O. ports 22 for connecting cables 24 to respective aircraft seats 12 (as will be discussed). Server 18 is preferably rectangular and relatively flat in shape and mounts to support plate 20 by a plurality of fasteners such as bolts that are positioned through an outer casing of server 18 and through.,support plate 20 . Support plate 20 is a generally rectangular and flat piece of material such as aluminum or plastic that has a pair of ears 26 disposed at corners along one side of support plate 20 . Ears 26 have apertures for allowing a fastening means to pass therethrough to secure the passenger interface unit 10 to the seat track 14 . The generally flat nature of server 18 and support plate 20 allow the passenger interface unit 10 to be easily positioned under the aircraft seat 12 without interfering with the feet of passenger sitting in the seat behind the passenger seat under which the passenger interface unit. 10 is located. Support plate 20 has raised edges 28 on opposite sides of support plate 20 for maintaining and guiding cables 24 from server 18 to seat track 14 as will be described in greater detail.
Cover 30 is rectangular in shape and has downward extending edges, 32 that pass around the outer perimeter of server 18 and abut support plate 20 . Cover 30 is made of preferably plastic and protects server 18 from damage caused by feet of a passenger sitting behind the seat under which the server 18 is located. Cover 30 has a cut out section 34 that allows for a gap between cover 30 and support plate 20 when the cover 30 is attached to a support plate 20 . Cut out section 34 allows a passage for cables 24 to pass from server 18 to seat track 14 .
I.O. ports 22 are distributed length wise along opposite sides of the server 18 . Preferably, four I.O. ports are disposed per side. It is noted that I.O. ports 22 can be serial, parallel, Ethernet or any other known type of ports for communicating between a personal computer and the server 18 .
Referring now to FIG. 5, a magnified view of V in FIG. 4 is shown in greater detail. In FIG. 5, the attachment of one of ears 26 to seat track 14 is described. In FIG. 5, a sliding bolt 36 is shown having a head 38 that sits on an under side of groove 40 . As such, sliding bolt 36 is able to be slid along seat track 14 such that the positioning of sliding bolts 36 coincides with the most optimum location for passenger interface unit 10 . Accordingly, once sliding bolts 36 are positioned at their respective predetermined locations, apertures in ears 26 are passed over the tops of bolts 36 until abutting seat track 14 . Next, nut 42 is threaded to sliding bolt 36 to secure respective ears 26 to seat track 14 . It is noted that ears 26 have a slight angle with respect to the remainder of support plate 20 . This insures that after ears 26 are secure to seat track 14 , support plate 20 and therefore passenger interface unit 10 are positioned against the carpeting and floor of the aircraft.
Referring to FIG. 2 and FIG. 4, cables 24 extend from I.O. ports 22 and travel around the outer periphery of server 18 until exiting passenger interface unit through cut out section 34 . Cables 24 then enter under seat track cover 44 and travel along seat track 14 between seat track cover 44 and seat track 14 until reaching respective aircraft seats 12 . As shown in FIG. 2, at each respective aircraft seat 12 , cables 24 extend from seat track 14 up and through the frame of each aircraft seat 12 until terminating at an output area in the seat. As such, as can be seen by reviewing FIG. 2 and FIG. 3, each passenger interface unit 10 can supply network communication to a plurality of aircraft seats 12 within an aircraft 46 . Accordingly, by locating the passenger interface unit 10 above the floorboard of the aircraft 46 and by lockingly engaging the passenger interface unit to respective seat tracks 14 , the passenger interface unit is able to supply a plurality of aircraft seats 12 with network communication.
As a result of the above described installation, a passenger interface unit can be repositioned throughout aircraft 14 when desired without requiring major construction or leaving aesthetically unpleasing holes in portions of the aircraft where the passenger interface unit previously resided. Moreover, as the previous location of passenger interface unit 10 does not have a residual hole or aperture, injury to passengers and damage to the aircraft due to passengers potentially stepping through residual holes in the floor board is alleviated.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A passenger interface unit as provided that is positioned on a floor portion of an aircraft and attaches to a seat track on the aircraft floor portion. The passenger interface unit can be reattached to different locations long the seat track throughout the aircraft. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to a portable gun for dispensing flowable adhesive contained in a collapsible container. More particularly, the present invention relates to a pneumatically operated dispensing gun having an elongate barrel which accommodates an adhesive-filled collapsible tube for dispensing adhesive.
BACKGROUND OF THE INVENTION
[0002] Accurate application of various viscous materials such as adhesives and the like is typically achieved by the use of dispensing guns, most notably, caulking guns. A conventional caulking gun supports adhesive material in a tube or other container and is designed, by operation of the gun, to dispense or expel the adhesive through a nozzle at one end of the container. Many caulking guns of this type are manually operated in that repetitive actuation of a trigger moves a plunger-like piston into dispensing contact with the adhesive containing container. Continuous movement of the piston by hand operation provides for a continuous dispensing of the adhesive. Other guns of this type may be power driven, for example, by pneumatic operation. In these situations, air pressure is used to compress or collapse an adhesive containing tube to dispense the adhesive through the nozzle.
[0003] One specific use of such dispensing guns, by way of example, is to apply adhesives to floor joists where subflooring may be applied over the adhesively coated joists so as to fasten the subfloor to the joists. As may be appreciated, the gun must be capable of accurately dispensing the adhesive on the joist so that the proper amount of adhesive is applied with little waste. Many of the conventional dispensing guns, therefore, require the installer to operate the gun in close proximity to the floor joist. This would require the installer to have to kneel or bend to be close to the floor to accurately place the adhesive on the joists. Still further, the size of the guns requires frequent refilling which becomes time consuming and costly for installation.
SUMMARY OF THE INVENTION
[0004] The present invention provides a gun for dispensing a flowable adhesive contained in a collapsible tube which may be dispensed through an extending dispensing nozzle. The gun includes an elongate hollow barrel for accommodating the tube. The barrel has a closed first end and an open second end. The closed first end has an aperture therethrough for passage of the extending dispensing nozzle. A handle is attachable to the open end of the barrel for closing the open end. The handle has a connection port in communication with the hollow barrel for attachment to a source of pneumatic pressure. The handle further includes a trigger operably connected to a connection port to allow controlled flow of air pressure into the barrel which collapses the tube causing dispensing of the flowable adhesive therethrough.
[0005] The present invention provides an assembly which includes in combination an elongate adhesive dispensing gun, an elongate collapsible adhesive-containing tube having a dispensing nozzle at one end and guide attached to the nozzle.
[0006] In addition, a kit of parts is provided wherein the kit includes a plurality of different length barrels attachable to a handle at one end of the barrel. A cover encloses the other end of said barrel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a plan view of a dispensing gun of the present invention.
[0008] FIG. 2 is a plan view of the dispensing gun of FIG. 1 , partially in section, showing the internal passage of the barrel.
[0009] FIG. 3 is an enlarged perspective showing of a rear portion of the dispensing gun of FIG. 1 shown in the open condition.
[0010] FIG. 4 shows the dispending gun of FIG. 1 and alternative length barrels used in combination therewith.
[0011] FIGS. 5 and 6 show the front end of an alternative embodiment of a dispensing gun of the present invention, respectively, in an exploded and assembled condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The present invention provides a dispensing gun which pneumatically dispenses adhesive contained within a collapsible container such as an elongate collapsible tube having a tapered dispensing nozzle at one end. While the invention is described with respect to an elongate bag-like tube, other configurations are within the contemplation of the present invention.
[0013] Referring now to FIGS. 1 and 2 , the dispensing gun 10 of the present invention is shown. Dispensing gun 10 includes an elongate hollow barrel 12 which is preferably cylindrical in configuration. The barrel includes a first open end 14 and an opposed second open end 16 . The barrel further includes a generally hollow cylindrical passageway 18 extending between the ends 14 and 16 .
[0014] Attached to the first end 14 of barrel 12 is a cover 20 which closes the first end. The cover may be affixed to the first end of barrel 14 by well known attachment methods such as press fitting the cover 20 onto the end 14 . The cover is designed to attach to the first end of the barrel in a sealed air-tight fashion. Various sealed attachment techniques, including adhesive attachment, are within the contemplation of the present invention. As will be described in further detail hereinbelow, the cover 20 is configured to accommodate in sealed relationship the front end of a dispensing tube. In addition, the cover includes a central aperture 22 at a distal end thereof for accommodating the extending nozzle of the tube.
[0015] The second end 16 of barrel 12 supports thereon a handle 30 . Handle 30 is generally in the configuration of a pistol grip. However, other configurations are within the contemplation of the present invention.
[0016] Referring additionally to FIG. 3 , the pistol grip handle 30 is a two component device including a cap portion 32 and a grip portion 34 . The cap portion 30 is generally an annular member into which is fitted onto the second end 16 of barrel 12 . As with the first end 14 of barrel 12 , the second end 16 can be press fit or otherwise secured to the cap portion 32 . The cap portion is designed to attach to the second end of the barrel in an air-tight fashion. An adhesive may be used to effect such sealing. The cap portion 32 includes an elastomeric sealing member 36 which preferably is in the form of an O-ring. The sealing member 36 provides for sealed engagement of the grip portion 34 of handle 30 with the cap portion 32 . In that regard, the grip portion 34 is hingedly attached to cap portion 32 by a pivotal hinge 40 . Hinge 40 permits movement of the grip portion 34 with respect to the cap 32 between an open condition shown in FIG. 3 and a closed condition shown in FIGS. 1 and 2 . A releasable latch mechanism 42 , including a latch 44 and a catch 46 , provides for secure connection of the grip portion and the cap in the closed position.
[0017] Grip portion 34 further includes an operable trigger 48 which may be manually depressed by the user. The trigger is in operable connection with a pneumatic air connection port 50 . Connection port 50 includes a mating connector 52 which can be used to snap fit to a pneumatic line 54 which extends to a source of pressurized air 56 . The connection port 50 is in fluid communication with the grip portion 34 and cap portion 32 of handle 30 so as to establish fluid communication between the connection port and the interior 18 of barrel 12 . The trigger may be depressed to open and close the fluid communication path between the connection port 50 and the interior 18 of barrel 12 to selectively apply pressurized air to the barrel passageway. The pressurized air source 56 may be any conventional pneumatic source and may be either fixed such as in the use of an air compressor which is attached with a pneumatic hose or may be portable to move along with the gun 10 .
[0018] Turning again to FIGS. 1 and 2 , an adhesive tube 60 is shown. Adhesive tube 60 is an elongate member having a closed rear end 62 and an opposite tapered forward end 64 having dispensing nozzle 66 extending therefrom. Dispensing nozzle 66 is a conventional tapered dispensing nozzle which permits the nozzle to be severed at various lengths therealong to increase the dispensing opening. A cap 65 , shown in FIG. 1 , may cover the cut tip of the dispensing nozzle when not in use. The tube 60 is generally a bag-like collapsible member which may be collapsed upon application of pneumatic pressure to dispense the adhesive contents contained therein through the dispensing nozzle 66 .
[0019] Operation of the gun 10 of the present invention is shown with respect to FIG. 2 . The collapsible adhesive tube 60 is loaded into the barrel 12 with the handle 30 being in the open position as shown in FIG. 3 . The adhesive tube 60 is inserted into the passage 18 of the barrel until the nozzle extends through the opening in cover 20 . The front end of the tube 60 seats with the cover 20 establishing an air-tight seal. The grip portion 34 is then pivotally closed to cap portion 32 and latchably secured employing latch 42 . The gun 10 is connected to a source of compressed air 56 at connector 52 . Trigger 48 is depressed permitting flow of pressurized air through connection port 50 and into passage 18 of barrel 12 . Continuous pneumatic pressure applied to tube 60 results in collapsing of the tube and the dispensing of the adhesive contents through nozzle 66 . Release of trigger 48 stops the flow of air through connection port 50 and thereby stops the dispensing of adhesive through nozzle 66 . Thus, the present invention provides a pneumatically operated gun for dispensing adhesive from a collapsible tube. The amount of adhesive disposed can be controlled by controlling the air pressure as well as by the cutting of the nozzle.
[0020] Referring now to FIG. 4 , a further feature of the present invention is shown. As may be appreciated, the gun of the present invention may be used to dispense adhesive to various surfaces. Each of these surfaces may be at various distances from the installer who is applying the adhesive. For example, the installer may wish to apply adhesive to a relatively close surface, or in other situations, the surface to which the adhesive to be may be applied may be a distance from the installer. In these situations, the present invention provides a gun which allows for the selective attachment of different length barrels thereto.
[0021] As shown in FIG. 4 , an assembly 11 may be provided where a plurality of different length barrels 12 a , 12 b and 12 c may be employed. The installer would have the option to selectively use the desired length barrel by attaching the selected barrel to the handle 30 and cover 20 . For example, where the installer wishes to apply adhesive to a surface in close proximity to the installer, a small length barrel 12 a may be applied. In other situations, particularly in situations where the installer wishes to apply adhesive to floor joists for subsequent application of a subflooring, the installer may use the extended length barrel 12 c . In such an instance, the installer may operate the adhesive gun to apply adhesive directly on the floor joists without having to kneel or bend to be close to the application location. While three barrel lengths are shown in FIG. 4 , it is of course within the contemplation of the present application that the gun assembly may be provided with barrels of other numbers and lengths.
[0022] The ability to change or select barrel lengths also provides the ability to accommodate different sizes of adhesive tubes. Use of larger volume adhesive tubes would result in the need to less frequently reload the gun with another tube.
[0023] Referring now to FIGS. 5 and 6 , a further embodiment of the present invention is shown. FIGS. 5 and 6 shows the front end of barrel 12 ′ where the cap portion of the barrel is integrally formed. Thus, the front end 14 ′ of barrel 12 ′ terminates in a closed front end 15 ′. The closed front end 15 ′ has a central aperture 22 ′ therethrough which is surrounded by an extended externally threaded collar 19 ′. The nozzle 66 of tube 60 extends through the opening 22 ′ and the threaded collar 19 ′.
[0024] The present invention further provides an alignment guide 70 which may be attached to the closed front end 15 ′ of barrel 10 ′. While the alignment guide is shown in use with the embodiments of FIGS. 5 and 6 , it may be appreciated that the alignment guide may be used with the embodiments of FIGS. 1-4 .
[0025] Alignment guide 70 includes a back wall 72 , a bottom wall 74 and a pair spaced apart guide walls 76 and 78 . The guide walls have outwardly directed distal feet 80 and 82 . The back wall 72 includes a generally U-shaped passageway 84 which is engageable about the extending threaded collar 16 ′. A threaded nut 85 is used to secure the alignment member 70 to the front end 15 ′ of barrel 12 ′. As shown in FIG. 6 , the alignment guide 70 when attached to the front end 15 ′ of barrel 12 ′ extends approximately the length of the extending nozzle 66 . The outwardly directed feet 80 and 82 serve as positioners so that when the installer is applying adhesive to a surface such as a floor joist, the feet stabilize the nozzle during movement along the joist. This allows the installer to accurately place the proper amount of adhesive at the proper location on the joist. This results in accurate application and less waste.
[0026] While the invention has been described in relationship to the preferred embodiments, it will be understood by those skilled in the art that various changes may be made without deviating from the fundamental nature and scope of the invention as defined in the appended claims. | A portable gun provides for the dispensing of flowable adhesives. The gun accommodates a flowable adhesive contained in a collapsible container which adhesive is dispensed through an extending dispensing nozzle. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of U.S. published patent application 2006-0062922-A1, filed as U.S. patent application Ser. No. 10/948,511 on Sep. 23, 2004 entitled “Polymerization Technique to Attenuate Oxygen Inhibition of Solidification of Liquids and Composition Therefor,” which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
The field of invention relates generally to nano-fabrication of structures. More particularly, the present invention is directed to methods for controlling distribution of fluid components on a body in imprint lithographic processes.
Nano-scale fabrication involves the fabrication of very small structures, e.g., having features on the order of one nanometer or more. A promising process for use in nano-scale fabrication is known as imprint lithography. Exemplary imprint lithography processes are described in detail in numerous publications, such as United States published patent application 2004/0065976 filed as U.S. patent application Ser. No. 10/264,960, entitled “Method and a Mold to Arrange Features on a Substrate to Replicate Features having Minimal Dimensional Variability”; United States published patent application 2004/0065252 filed as U.S. patent application Ser. No. 10/264,926, entitled “Method of Forming a Layer on a Substrate to Facilitate Fabrication of Metrology Standards”; and U.S. Pat. No. 6,936,194, issued Aug. 30, 2005 and entitled “Functional Patterning Material For Imprint Lithography Processes,” all of which are assigned to the assignee of the present invention.
Referring to FIG. 1 , the basic concept behind imprint lithography is forming a relief pattern on a substrate that may function as, inter alia, an etching mask so that a pattern may be formed into the substrate that corresponds to the relief pattern. A system 10 employed to form the relief pattern includes a stage 11 upon which a substrate 12 is supported, and a template 14 having a mold 16 with a patterning surface 18 thereon. Patterning surface 18 may be substantially smooth and/or planar, or may be patterned so that one or more recesses are formed therein. Template 14 is coupled to an imprint head 20 to facilitate movement of template 14 . A fluid dispense system 22 is coupled to be selectively placed in fluid communication with substrate 12 so as to deposit polymerizable material 24 thereon. A source 26 of energy 28 is coupled to direct energy 28 along a path 30 . Imprint head 20 and stage 11 are configured to arrange mold 16 and substrate 12 , respectively, to be in superimposition, and disposed in path 30 . Either imprint head 20 , stage 11 , or both vary a distance between mold 16 and substrate 12 to define a desired volume therebetween that is filled by polymerizable material 24 .
Typically, polymerizable material 24 is disposed upon substrate 12 before the desired volume is defined between mold 16 and substrate 12 . However, polymerizable material 24 may fill the volume after the desired volume has been obtained. After the desired volume is filled with polymerizable material 24 , source 26 produces energy 28 , which causes polymerizable material 24 to solidify and/or cross-link, forming polymeric material conforming to the shape of the substrate surface 25 and mold surface 18 . Control of this process is regulated by processor 32 that is in data communication with stage 11 imprint head 20 , fluid dispense system 22 , and source 26 , operating on a computer-readable program stored in memory 34 .
An important characteristic with accurately forming the pattern in the polymerizable material is to reduce, if not prevent, adhesion to the mold of the polymeric material, while ensuring suitable adhesion to the substrate. This is referred to as preferential release and adhesion properties. In this manner, the pattern recorded in the polymeric material is not distorted during separation of the mold. Prior art attempts to improve the release characteristics employ a release layer on the surface of the mold. The release layer is typically hydrophobic and/or has low surface energy. The release layer adheres to the mold by covalent chemical bonding. Providing the release layer improves release characteristics. This is seen by minimization of distortions in the pattern recorded into the polymeric material that are attributable to mold separation. This type of release layer is referred to, for purposes of the present discussion, as an a priori release layer, i.e., a release layer that is solidified to the mold.
Another prior art attempt to improve release properties is described by Bender et al. in “Multiple Imprinting in UV-based Nanoimprint Lithography: Related Material Issues,” Microeletronic Engineering 61-62 (2002), pp. 407-413. Specifically, Bender et al. employ a mold having an a priori release layer in conjunction with a fluorine-treated UV curable material. To that end, a UV curable layer is applied to a substrate by spin-coating a 110 cPs UV curable fluid to form a UV curable layer. The UV curable layer is enriched with fluorine groups to improve the release properties.
A need exists, therefore, to improve the preferential release and adhesion properties of a mold employed in imprint lithography processes.
SUMMARY OF THE INVENTION
The present invention provides a method of controlling the distribution of a fluid on a body that features compensating for varying distribution of constituent components of a composition that move over a surface of a substrate. Specifically, the quantity of a surfactant component of a composition varied over the surface upon which the composition was spread to form a contiguous layer. Typically, the composition is deposited upon the surface as a plurality of spaced-apart droplets. It was discovered that the air-liquid interface of each droplet varied in dimension as the same was spread over the surface. This resulted in there being a depletion of surfactants, referred to as surfactant depletion regions (SDR) in the area of the contiguous layer proximate to the situs of the droplets and a surfactant rich region (SRR) in area of the layer located proximate to spaces between the droplets. This is believed to increase the probability that pitting of a solidified layer formed from the contiguous layer occurs. The pitting is believed to be attributable to, inter alia, from an uneven distribution of surfactant on the mold. A lamella layer is generated on the mold after each imprint. The lamella layer is formed primarily from surfactants present in the material disposed between the mold and the substrate during imprinting. An uneven distribution of surfactants in this material causes an uneven distribution of surfactants in the lamella layer. This in turn exacerbates the differences in surfactant quantities in the SDR and SRR as the number of imprints increases. To compensate for the varying distribution of surfactants in a given layer, the method includes generating a sequence of patterns of liquid upon a substrate, each of which includes a plurality of spaced-apart liquid regions, with interstices being defined between adjacent liquid regions. A second of the patterns of liquid of the sequence is arranged so that the liquid regions associated therewith are in superimposition with the interstices of a first of the patterns of liquid of the sequence. These and other embodiments are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified plan view of a lithographic system in accordance with the prior art;
FIG. 2 is a simplified elevation view of a template and imprinting material disposed on a substrate in accordance with the present invention;
FIG. 3 is a top down view of a region of the substrate, shown in FIG. 2 , upon which patterning occurs employing a pattern of droplets of polymerizable fluid disposed thereon;
FIG. 4 is a simplified elevation view of an imprint device spaced-apart from the patterned imprinting layer, shown in FIG. 1 , after patterning in accordance with the present invention;
FIG. 5 is a detailed view of the template, shown in FIG. 2 being removed after solidification of imprinting material in accordance with a second embodiment of the present invention;
FIG. 6 is a cross-sectional view of an imprinted layer showing varying thickness that the present invention is directed to reduce if not avoid;
FIG. 7 is a top down view of a region of the substrate, shown in FIG. 2 , showing an intermediate pattern formed by the droplets of polymerizable fluid shown in FIG. 3 , during spreading;
FIG. 8 is a detailed cross-sectional view of a portion of one droplet of imprinting material showing the change in shape of the same during formation of intermediate pattern in accordance with the present invention;
FIG. 9 is a detailed cross-sectional view of a portion of one droplet of imprinting material showing the change is surfactant molecule distribution as the shape of the same changes during formation of intermediate patterns; and
FIG. 10 is a partial top down view of FIG. 3 showing a sequence of droplets deposited on a surface in furtherance of forming a sequence of contiguous layers of imprinting material in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2 , a mold 36 , in accordance with the present invention, may be employed in system 10 , and may define a surface having a substantially smooth or planar profile (not shown). Alternatively, mold 36 may include features defined by a plurality of spaced-apart recessions 38 and protrusions 40 . The plurality of features defines an original pattern that forms the basis of a pattern to be formed on a substrate 42 . Substrate 42 may comprise a bare wafer or a wafer with one or more layers disposed thereon, one of which is shown as primer layer 45 . To that end, reduced is a distance “d” between mold 36 and substrate 42 . In this manner, the features on mold 36 may be imprinted into a conformable region of substrate 42 , such as an imprinting material disposed on a portion of surface 44 that presents a substantially planar profile. It should be understood that the imprinting material may be deposited using any known technique, e.g., spin-coating, dip coating and the like. In the present example, however, the imprinting material is deposited as a plurality of spaced-apart discrete droplets 46 on substrate 42 .
Referring to both FIGS. 3 and 4 , droplets 46 are arranged in a pattern 49 to facilitate formation of a contiguous layer 50 . Imprinting material is formed from a composition that may be selectively polymerized and cross-linked to record the original pattern therein, defining a recorded pattern. Specifically, the pattern recorded in the imprinting material is produced, in part, by interaction with mold 36 , e.g., electrical interaction, magnetic interaction, thermal interaction, mechanical interaction or the like. In the present example, mold 36 is spaced-apart from substrate 42 with the area of surface 44 in superimposition therewith being shown by periphery 51 . Portions of surface 44 not covered by droplets 46 and within periphery 51 define voids 53 . Regions of mold 36 in superimposition with droplets 46 define deposition zones. It should be understood that for purposes of the present example, each side of periphery 51 is 25 millimeters in length, i.e., the area encompassed by periphery is 25×25 mm square. Droplets 46 are shown to reflect an accurate depiction of proportional size a diameter thereof compared to the length of one side of periphery 51 . Although droplets 46 are shown being different sizes, the present invention envisions an embodiment wherein all the droplets 46 are of the same size, i.e., contain the same quantity of liquid. Regions of mold 36 in superimposition with voids 53 define interstices. Mold 36 comes into mechanical contact with the imprinting material, spreading droplets 46 , so as to generate a contiguous layer 50 of the imprinting material over surface 44 . In one embodiment, distance “d” is reduced to allow sub-portions 52 of imprinting material to ingress into and fill recessions 38 . To facilitate filling of recessions 38 , before contact between mold 36 and droplets 46 , the atmosphere between mold 36 and droplets 46 is saturated with helium or is completely evacuated or is a partially evacuated atmosphere of helium. It may be desired to purge the volume, defined between mold 36 , surface and droplets 46 , shown in FIG. 2 , for example with Helium gas flowed at 5 pounds per square inch (psi), before contact occurs. An exemplary purging technique is disclosed in U.S. Pat. No. 7,090,716 issued Aug. 15, 2006, entitled SINGLE PHASE FLUID IMPRINT LITHOGRAPHY, which is incorporated by reference herein.
The imprinting material is provided with the requisite properties to completely fill recessions 38 while covering surface 44 with a contiguous formation of the imprinting material. In the present embodiment, sub-portions 54 of imprinting material in superimposition with protrusions 40 remain after the desired, usually minimum, distance “d” has been reached. This action provides contiguous layer 50 with sub-portions 52 having a thickness t 1 , and sub-portions 54 , having a thickness t 2 . Thicknesses “t 1 ,” and “t 2 ” may be any thickness desired, dependent upon the application. Thereafter, contiguous layer 50 is solidified by exposing the same to the appropriate curing agent, e.g., actinic energy, such as broadband ultra violet energy, thermal energy or the like, depending upon the imprinting material. This causes the imprinting material to polymerize and cross-link. The entire process may occur at ambient temperatures and pressures, or in an environmentally-controlled chamber with desired temperatures and pressures. In this manner, contiguous layer 50 is solidified to provide side 56 thereof with a shape conforming to a shape of a surface 58 of mold 36 .
Referring to FIGS. 1 , 2 and 3 , the characteristics of the imprinting material are important to efficiently pattern substrate 42 in light of the unique patterning process employed. For example, it is desired that the imprinting material have certain characteristics to facilitate rapid and even filling of the features of mold 36 so that all thicknesses t 1 are substantially uniform and all thicknesses t 2 are substantially uniform. To that end, it is desirable that the viscosity of the imprinting material be established, based upon the deposition process employed, to achieve the aforementioned characteristics. As mentioned above, the imprinting material may be deposited on substrate 42 employing various techniques. Were the imprinting material deposited as a plurality of discrete and spaced-apart droplets 46 , it would be desirable that a composition from which the imprinting material is formed have relatively low viscosity, e.g., in a range of 0.5 to 30 centipoises (cPs).
Considering that the imprinting material is spread and patterned concurrently, with the pattern being subsequently solidified into contiguous layer 50 by exposure to radiation, it would be desired to have the composition wet surface of substrate 42 and/or mold 36 and to avoid subsequent pit or hole formation after polymerization. Were the imprinting material deposited employing spin-coating techniques, it would be desired to use higher viscosity materials, e.g., having a viscosity greater than 10 cPs and typically, several hundred to several thousand cPs, with the viscosity measurement being determined in the absence of a solvent. The total volume contained in droplets 46 may be such so as to minimize, or avoid, a quantity of the imprinting material from extending beyond the region of surface 44 in superimposition with mold 36 , while obtaining desired thicknesses t 1 and t 2 , e.g., through capillary attraction of the imprinting material with mold 36 and surface 44 and surface adhesion of the imprinting material.
In addition to the aforementioned characteristics, referred to as liquid phase characteristics, it is desirable that the composition provides the imprinting material with certain solidified phase characteristics. For example, after solidification of contiguous layer 50 , it is desirable that preferential adhesion and release characteristics be demonstrated by the imprinting material. Specifically, it is beneficial for the composition from which the imprinting material is fabricated to provide contiguous layer 50 with preferential adhesion to substrate 42 and preferential release of mold 36 . In this fashion, reduced is the probability of distortions in the recorded pattern resulting from the separation of mold 36 therefrom due to, inter alia, tearing, stretching or other structural degradation of contiguous layer 50 .
For example, with reference to FIGS. 4 and 5 , upon separation of mold 36 , contiguous layer 50 is subjected to a separation force Fs. Separation force Fs is attributable to a pulling force F P on mold 36 and adhering forces, e.g., Van der Waals forces, between contiguous layer 50 and mold 36 . Pulling force F P is used to break vacuum seal. It is desired to decouple mold 36 from contiguous layer 50 without unduly distorting contiguous layer 50 . One manner in which to control distortion of contiguous layer 50 during separation of mold 36 therefrom is by providing the composition from which the imprinting material is formed with releasing agents, such as surfactants.
The constituent components of the composition that form the imprinting material and layer 45 to provide the aforementioned characteristics may differ. This results from substrate 42 being formed from a number of different materials, i.e. providing differing magnitudes of adhering forces F A . As a result, the chemical composition of surface 44 varies dependent upon the material from which substrate 42 is formed. For example, substrate 42 may be formed from silicon, plastics, gallium arsenide, mercury telluride, and composites thereof. As mentioned above, substrate 42 may include one or more layers shown as primer layer 45 , e.g., dielectric layer, metal layer, semiconductor layer, planarization layer and the like, upon which contiguous layer 50 is generated. To that end, primer layer 45 would be deposited upon a wafer 47 employing any suitable technique, such as chemical vapor deposition, spin-coating and the like. Additionally, primer layer 45 may be formed from any suitable material, such as silicon, germanium and the like. Additionally, mold 36 may be formed from several materials, e.g., fused-silica, quartz, indium tin oxide diamond-like carbon, MoSi, sol-gels and the like.
An exemplary composition that may be employed from which to form contiguous layer 50 is as follows:
Composition
isobornyl acrylate
n-hexyl acrylate
ethylene glycol diacrylate
2-hydroxy-2-methyl-1-phenyl-propan-1-one
R 1 R 2
An acrylate component of the bulk material, isobornyl acrylate (IBOA), has the following structure:
and comprises approximately 47% of COMPOSITION by weight, but may be present in a range of 20% to 80%, inclusive. As a result, the mechanical properties of solidified imprinting layer 134 are primarily attributable to IBOA. An exemplary source for IBOA is Sartomer Company, Inc. of Exton, Pa. available under the product designation SR 506.
The component n-hexyl acrylate (n-HA) has the following structure:
and comprises approximately 25% of bulk material by weight, but may be present in a range of 0% to 40%, inclusive. Also providing flexibility to formation 50 , n-HA is employed to reduce the viscosity of the prior art bulk material so that bulk material, in the liquid phase, has a viscosity in a range 2-9 Centipoises, inclusive. An exemplary source for the n-HA component is the Aldrich Chemical Company of Milwaukee, Wis.
A cross-linking component, ethylene glycol diacrylate, has the following structure:
and comprises approximately 15% of bulk material by weight, and may be present in a range of 10% to 50%, inclusive. EGDA also contributes to the modulus and stiffness buildup, as well as facilitates cross-linking of n-HA and IBOA during polymerization of the bulk material.
An initiator component, 2-hydroxy-2-methyl-1-phenyl-propan-1-one, is available from Ciba Specialty Chemicals of Tarrytown, N.Y. under the trade name DAROCUR® 1173, and has the following structure:
and comprises approximately 3% of the bulk material by weight, and may be present in a range of 1% to 5%, inclusive. The initiator is responsive to a broad band of ultra-violet radiation generated by a medium-pressure mercury lamp. In this manner, the initiator facilitates cross-linking and polymerization of the components of the bulk material. The constituent components of COMPOSITION, IBOA, n-HA, EGDA and 2-hydroxy-2-methyl-1-phenyl-propan-1-one form the bulk material of the same.
A surfactant component, R 1 R 2 , is a non-ionic surfactant sold by Mason Chemical Company of Arlington Heights, Ill. under the product names MASURF® FS-2000. The surfactant component consists of approximately 2%, by weight, of the bulk material and acts as a release agent of COMPOSITION by facilitating preferential adhesion and release of contiguous layer 50 , once solidified.
The advantages of this patterning process are manifold. For example, the thickness differential between protrusions 40 and recessions 38 facilitates formation, in substrate 42 , of a pattern corresponding to the recorded pattern formed in contiguous layer 50 . Specifically, the thickness differential between t 1 and t 2 of protrusions 40 and recession 38 , respectively, results in a greater amount of etch time being required before exposing regions of substrate 42 in superimposition with protrusions 40 compared with the time required for regions of substrate 42 in superimposition with recession 52 being exposed. For a given etching process, therefore, etching will commence sooner in regions of substrate 42 in superimposition with recessions 38 than regions in superimposition with protrusions 40 . This facilitates formation of a pattern in substrate corresponding to the aforementioned recorded pattern. By properly selecting the imprinting materials and etch chemistries, the relational dimensions between the differing features of the pattern eventually transferred into substrate 42 may be controlled as desired. To that end, it is desired that the etch characteristics of the recorded pattern, for a given etch chemistry, be substantially uniform.
As a result, the characteristics of the imprinting material are important to efficiently pattern substrate 42 in light of the unique patterning process employed. As mentioned above, the imprinting material is deposited on substrate 42 as a plurality of discrete and spaced-apart droplets 46 . The combined volume of droplets 46 is such that the imprinting material is distributed appropriately over an area of surface 44 where the recorded pattern is to be formed. In this fashion, the total volume of the imprinting material in droplets 46 defines the distance “d”, to be obtained so that the total volume occupied by the imprinting material in the gap defined between mold 36 and the portion of substrate 42 in superimposition therewith once the desired distance “d” is reached is substantially equal to the total volume of the imprinting material in droplets 46 . To facilitate the deposition process, it is desired that the imprinting material provide rapid and even spreading of the imprinting material in droplets 46 over surface 44 so that all thicknesses t 1 are substantially uniform and all residual thicknesses t 2 are substantially uniform.
Referring to FIGS. 3 and 6 , a problem recognized by the present invention involves varying characteristics of a contiguous layer of imprinting material. Specifically, formed on a substrate 142 was a layer 100 in the manner discussed above, i.e., except with a non-patterned mold (not shown) having a smooth surface, to spread droplets 46 . After spreading of droplets 46 the imprinting material was exposed for approximately 700 ms to actinic energy having a wavelength of approximate 365 nm a flux of 77 mW/cm 2 to solidify the same. After sequentially forming and solidifying several layers 100 employing mold 36 , observed were pits 102 over the area of layers 100 formed later in the sequence. Pits 102 were found to be a complete absence of layer 100 in superimposition with portions 104 of substrate 142 and located between portions 106 of layer 100 having a desired thickness. It is believed that pits 102 result from an uneven surfactant distribution over layer 100 that prevents the bulk material of COMPOSITION from being in superimposition with regions 104 . The difference becomes more pronounced as the number of layers 100 imprinted.
Referring to FIGS. 3 , 4 and 6 , the present invention overcomes these drawbacks by changing the position of droplets 46 in pattern 49 on sequential formation of contiguous layers, such as contiguous layer 50 or 100 . The present discussion concerns contiguous layer 100 , with the understanding that the same applies to contiguous layer 50 , as well. Specifically, it was found that the quantity of the surfactant component of COMPOSITION varied in contiguous layer 100 over the surface upon which the composition was spread to form solidified contiguous layer 100 . Typically, the composition is deposited upon surface 44 as a plurality of spaced-apart droplets 46 . It was discovered that the surfactant concentration in the air-liquid interface of each droplet varied as the droplet was spread over the surface. This resulted from several factors, including the viscosity differential between the surfactant component of COMPOSITION and the bulk material component of the same and the consumption of the surfactant component by clinging to the mold 36 surface in contact with the COMPOSITION. The presented as surfactant depletion regions (SDR) in the area of the contiguous layer proximate to the situs of the droplets 46 , regions 106 , and a surfactant rich region (SRR) in areas of the layer located proximate to spaces between the droplets, regions 104 .
Referring to FIGS. 3 , 8 and 9 , observing that surfactants have an affinity for the region of a liquid proximate to a liquid-air interface it was realized that during formation of a contiguous layer, surfactant molecules underwent redistribution due to the varying size of the liquid-air-interface. Upon deposition of droplets 46 on surface 44 , each of the droplets 46 generates an initial liquid-air interface 120 . Surfactant molecules 122 are packed tightly, after a predetermined time, at interface 120 . As mold 36 interacts with droplets 46 , liquid in droplets 46 moves with respect to substrate 42 , in direction of the movement shown by arrow 124 forming a series of intermediate patterns, such as pattern 110 , before droplets 46 merge to form contiguous layer 100 . As droplets 46 move the air-liquid interface 120 moves, shown by liquid-air interface 220 , which finally becomes ambient-air interface 108 , shown in FIG. 7 . This results in the spacing between adjacent surfactant molecules 122 increasing, shown in FIG. 9 , for the reasons discussed above. As a result, a greater number of surfactant molecules travel from regions of liquids in superimposition with deposition zones of mold 36 , creating SDR regions thereat, and an SRR region in areas of liquid in superimposition with interstices of mold 36 , shown in FIG. 4 .
Referring to FIGS. 4 , 6 , 8 and 9 , the presence of surfactant molecules 122 in contiguous layer 100 generates a lamella layer 150 on mold 36 after formation of each contiguous layer 100 . Lamella layer 150 comprises a densely packed fluid composition of surfactant molecules 122 . The distribution of surfactant molecules 122 in lamella layer 150 matches the distribution of surfactant molecules in contiguous layer 100 , i.e. SDR regions 102 and SRR region 104 . Thus, there is an uneven distribution of surfactant molecules 122 in lamella layer 150 . On formation of subsequent contiguous layers, the difference in surfactant molecule distribution in lamella layer 150 may become exacerbated, resulting in an increasing probability that voids may be present in contiguous layer 100 . To reduce, if not avoid an uneven distribution of surfactant molecules 122 in layers 100 and 150 , a subsequent layer formed by mold 36 would be generated by locating deposition zones of the same to be in superimposition with interstices of a previously formed contiguous layer 100 that includes regions 104 , shown more clearly in FIG. 10 .
Referring again to FIGS. 4 , 6 , 8 and 9 , in this manner, the existing surfactant molecule 122 distribution present in lamella 150 may be compensated for, at least in part, by the resulting surfactant molecule 122 distribution from spreading of droplets 46 to form contiguous layer 100 . This is referred to as a droplet pattern shift in which sequential contiguous layers formed from COMPOSITION is generated by shifting the droplets in the pattern for one of the contiguous layers in the sequence compared to the position of the droplets in the pattern employed to form the previous contiguous layer in the sequence.
Referring to FIG. 10 , it should be understood, however, that it need not be necessary to shift the pattern 49 of droplets so that the entire area of droplets 46 are in superimposition with the interstices. Rather, it is within the spirit of the present invention that there may be an overlap between droplets 46 of one pattern and droplets 146 of the next pattern formed in a sequence. This may be repeated until a pattern is formed corresponding to a subsequent contiguous layer the area of which is entirely within a void 53 of an initial pattern and, therefore, the interstice. Moreover, it may be desirable to vary the quantity of surfactants in one or more of droplets 46 , 146 , 246 and 346 to avoid pitting of contiguous layer 100 , shown in FIG. 6 .
The embodiments of the present invention described above are exemplary. Many changes and modifications may be made to the disclosure recited above while remaining within the scope of the invention. The scope of the invention should not, therefore, be limited by the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents. | The present invention provides a method of controlling the distribution of a fluid on a body that features compensating for varying distribution of constituent components of a composition that moved over a surface of a substrate. To that end, the method includes generating a sequence of patterns of liquid upon a substrate, each of which includes a plurality of spaced-apart liquid regions, with voids being defined between adjacent liquid regions. A second of the patterns of liquid of the sequence is arranged so that the liquid regions associated therewith are in superimposition with the voids of a first of the patterns of liquid of the sequence. | 1 |
This application claims priority to U.S. Provisional Patent Application No. 60/885,102 filed on Jan. 16, 2007 and incorporates it by reference in its entirety.
FIELD OF THE INVENTION
This application relates to paintball markers and, more particularly, to a paintball marker conversion unit to allow a paintball marker to fire projectiles other than paintballs.
BACKGROUND OF THE INVENTION
Paintball markers are widely used in various recreational environments, such as simulated war games where the intent to shoot at an opposing player with a paintball, thus marking the opposing player with a particular paint color. Paintball markers using compressed air or gas for power are well known. Typically paintball markers are pneumatically powered, i.e., compressed air or gas powered, and mechanically operated markers are pneumatically powered.
Paintball markers are manufactured in a variety of shapes and sizes and have different types of internal mechanisms or actions therein. The internal mechanism or action is housed in a receiver of the marker. A magazine for holding a plurality of paintballs is connectable to the marker. Such markers include all elongated barrel, which extends from the receiver and from which the projectile is discharged, and a trigger housing connected to the receiver. The trigger housing carries a trigger mechanism, which includes a manually operated trigger for controlling the discharge of projectiles from the marker.
The sportsman that enjoys paintball markers may also have an interest in small caliber pneumatically powered projectile conveyors as well. The ammunition fired by a small caliber pneumatically powered projectile conveyors includes, but is not limited to, .177 caliber BBs, .177 caliber pellets, .25 caliber ball bearings, 6 mm airsoft rounds, and other small caliber ammunition. These various types of ammunition can be fired pneumatically, as well as mechanically. Because there is a plurality of small caliber ammunition that can be fired pneumatically, there arises a need for a universal device that can fire a wide range of projectiles pneumatically.
The sportsman wishing to use a small caliber, pneumatically powered, projectile conveyors has a need for the increased versatility of a device that can fire a plurality of types of projectiles.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the invention, a paintball marker, a projectile staging mechanism, and an adapter comprise an apparatus able to fire a plurality of different types and sizes of projectiles. The paintball marker, which would have its standard barrel removed, includes a pneumatically-powered firing mechanism, and an input for receiving paintballs. The projectile staging mechanism, which receives and subsequently fires the plurality of different projectiles, attaches to the paintball marker in the place of the removed standard barrel. An adapter fits between the paintball marker and the projectile staging mechanism to mount or attach the paintball marker to the projectile staging mechanism.
In a specific embodiment, a paintball marker conversion unit includes a projectile staging mechanism having a barrel with a projectile inlet hole position along a sidewall of the barrel. The projectile staging mechanism has an attachment end. An adapter has first and second ends where the first end is selectively removeably coupled to the attachment end of the projectile staging mechanism and the second end is configured to selectively removeably couple to a paintball marker. The adapter further has a tube with a first end slideably engaging the barrel of the projectile staging mechanism and a second end configured to engage the paintball marker when the adapter is coupled to the paintball marker. When a trigger of the paintball marker is activated the tube moves forward to generally seal the projectile inlet hole and allow pressurized gas from the paintball marker to discharge the projectile out of the barrel.
The first and second ends of the adapter may be threaded. In addition, the adapter may include a retaining ring to rotatingly fix the adapter to the attachment end of the projectile staging mechanism. In so doing, the projectile staging mechanism can be fixed at a desired rotational angle relative to the paintball marker.
The projectile staging mechanism may include a magazine well for receiving and retaining a magazine suitable for holding projectiles. In that regard, the magazine well may include a magazine retaining mechanism that is selectively moveable to release a magazine retained in the magazine well. In one example, the magazine retaining mechanism includes a lever and oppositely disposed buttons. Either the lever or the two buttons may be operated to release a magazine from the magazine well.
In one embodiment of the paintball marker conversion unit the barrel has a first diameter and the tube has second diameter. The first diameter is greater than the second diameter such that the tube may slide inside of the barrel, such as when the projectile is fired out of the projectile staging mechanism. In another embodiment, the first diameter is less than the second diameter such that the tube slides over of the barrel such as when the projectile is fired out of the projectile staging mechanism.
In one embodiment, sometimes referred to as an indirect drive embodiment, the adapter includes a bias member, such as a spring, that is operatively couple to the tube so as to bias the tube toward the paintball marker. This arrangement creates an essentially airtight seal between the tube and paintball marker when the adapter is coupled to the paintball marker.
In another embodiment, sometimes referred to as an direct drive embodiment, the tube has a threaded end that couples to a bolt of the paintball marker when the adapter is coupled to the paintball marker. As such, the tube and bolt move together when the paintball marker is fired.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a perspective view of a paintball marker conversion unit mounted to conventional paintball marker.
FIG. 2 is a disassembled perspective view of the paintball conversion unit and conventional paintball marker of FIG. 1 .
FIG. 3A is a partial cross-sectional view of the paintball marker conversion unit and conventional paintball marker of FIG. 1 shown with a projectile in the barrel and the tube fully retracted.
FIG. 3B is a partial cross-sectional view of the paintball marker conversion unit and conventional paintball marker of FIG. 3A shown with the tube contacting the projectile and covering the projectile inlet hole.
FIG. 3C is a partial cross-sectional view of the paintball marker conversion unit and conventional paintball marker of FIG. 3A shown with the tube in its forward most position and the projectile traveling down the barrel.
FIG. 3D is cross-sectional view of the tube contacting the projectile and covering the projectile inlet hole.
FIG. 4 is a disassembled perspective view of the magazine with a three-way release mechanism.
FIG. 5 is a cross-sectional view of the magazine of FIG. 4 taken along line 5 - 5 .
FIG. 6A is a cross-sectional view of the magazine of FIG. 5 taken along line 6 A- 6 A of FIG. 5 .
FIG. 6B is a cross-sectional view similar to FIG. 6A showing the magazine retaining mechanism in a released position.
FIG. 7A is a partial cross-sectional view of another embodiment of a paintball marker conversion unit and conventional paintball marker shown with a projectile in the chamber and the tube fully retracted.
FIG. 7B is a partial cross-sectional view of the paintball marker conversion unit and conventional paintball marker of FIG. 7A shown with the tube contacting the projectile and covering the projectile inlet hole.
FIG. 7C is a partial cross-sectional view of the paintball marker conversion unit and conventional paintball marker of FIG. 7A shown with the tube in its forward most position and the projectile traveling down the barrel.
FIG. 8A is an enlarged cross-sectional view of the tube sliding over the barrel just prior to covering the projectile inlet hole.
FIG. 8B is an enlarged cross-sectional view of the tube sliding over the barrel and covering the projectile inlet hole.
FIG. 8C is an enlarged cross-sectional view of the tube sliding over the barrel and the projectile advancing down the barrel.
DETAILED DESCRIPTION
Referring to FIG. 1 , a paintball marker conversion unit 10 is mounted to a conventional paintball marker 12 from an original equipment manufacturer. To mount the paintball marker conversion unit 10 to the paintball marker 12 , the stock barrel (not shown) that came with the conventional paintball marker 12 is unscrewed and in its place an adapter 14 is screwed in. The paintball marker conversion unit 10 includes a projectile staging mechanism 16 that screws onto the other end of the adapter 14 . Paintball marker 12 has a firing mechanism, which includes a bolt 18 ( FIG. 2 ) that is activated by compressed gas to fire projectiles. Typically, paintballs are fed to the paintball marker 12 through projectile port 20 . With the adapter 14 and projectile staging mechanism 16 in place, the projectiles are fed directly into projectile staging mechanism 16 instead of through projectile port 20 .
The projectile staging mechanism 16 can be coupled to a wide variety of conventional paintball markers—and not just those shown and described herein—so long as the appropriate adapter 14 is used. Because both ends of the adapter 14 are threaded, it is a relatively quick and easy process to couple and uncouple the projectile staging mechanism 16 to different paintball markers. In the end, the consumer needs to purchase only different adapters 14 , instead of different projectile staging mechanisms 16 , if he or she desires to utilize a different paintball marker 12 . Although the ends of adapter 14 are shown and described has being threaded, the ends of the adapter 14 may alternatively have other ways of connecting to the projectile staging mechanism 16 and the paintball marker 12 . By way of example, but not limitation, the ends may have quick disconnect mechanisms similar to those used on pneumatic tools. Such an arrangement would permit the operator to quickly disconnect one paintball marker 12 from the adapter 14 and attached a different paintball marker 12 without using any tools.
Referring now to FIGS. 2 and 3A , an indirect drive embodiment of projectile staging mechanism 16 of the present invention is illustrated. A receiver 22 is the main housing for the components of the direct drive embodiment of projectile staging mechanism 16 . One end of adapter 14 is threaded and is screwed into receiver 22 of the indirect drive embodiment of projectile staging mechanism 16 . The threaded mating surface between adapter 14 and receiver 22 allows the entire indirect drive embodiment of projectile staging mechanism 16 to be rotated and fixed at any angle relative to the longitudinal firing axis of paintball marker 12 thereby offering a variety of different shooting styles/options for the operator. For example, the projectile staging mechanism 16 can be rotated or angled to allow magazine 24 to feed in a vertical, horizontal, or other angular position. The projectile staging mechanism 16 is threaded onto adapter 14 until the desired angle between the projectile staging mechanism 16 and the paintball marker 12 has been achieved, then a retaining ring 26 on adapter 14 is tightened against projectile staging mechanism 16 to hold projectile staging mechanism 16 at the desired angle.
The projectile staging mechanism 16 includes a barrel 28 and a tube 30 . Tube 30 and barrel 28 work in concert to facilitate firing of a projectile. In this embodiment, tube 30 is coupled to tube bolt adapter 32 , which abuts bolt 18 of paintball marker 12 to create a pressure seal therewith. As such, when bolt 18 moves forward, so does tube 30 . A recuperator spring 42 and recuperator spring guide 44 bias the tube bolt adapter 32 to a rearward position ( FIG. 3A ) but not necessarily into bolt 18 . Recuperator spring 42 returns the tube 30 to its pre-firing position. When the trigger of paintball marker 12 is pulled, the paintball marker's recoil spring forces bolt 18 forward, and thusly tube 30 forward. With further reference to FIGS. 3B and 3D , barrel 28 includes a projectile inlet hole 34 from which projectiles 35 are received from the magazine 24 . The diameter of tube 30 may be larger or smaller than barrel 28 . When tube 30 is brought forward by bolt 18 , tube 30 slides along an interior surface of the barrel 28 (in the case where tube 30 has a smaller diameter than barrel 28 ) and over projectile inlet hole 34 to create an airtight seal therewith. Projectile inlet hole 34 is located in the sidewall of the barrel 28 to receive projectiles 35 being held in the magazine 24 . The tight seal enables essentially all of the compressed gas to fire the projectile 35 out of the projectile staging mechanism 16 . At rest, bolt 18 is held to the rear until the operator pulls the trigger. When the trigger is pulled, bolt 18 is released and propelled forward toward the muzzle via a compression spring (not shown). Bolt 18 and tube 30 travel forward to advance the next projectile 35 presented in barrel 28 . Then, the paintball marker 12 releases compressed gas to propel the round out of barrel 28 . Advantageously, the tube 30 pushes the projectile forward and seals the projectile inlet hole 34 prior to the release of the compressed gas. Consequently, essentially all of the compressed gas is available to fire the projectile 35 with greater force than if the projectile inlet hole 34 was left unsealed. Once bolt 18 and tube 30 has traveled approximately one inch, the bolt 18 depresses a main valve in paintball marker 12 thereby releasing a fixed quantity of high-pressure gas, just as it would if it were firing a standard paintball projectile. The compressed gas travels through bolt 18 and then tube 30 . The gas exits the end of tube 30 where it impacts and accelerates the projectile 35 down barrel 28 . See FIG. 3C . The compressed gas also acts against bolt 18 and tube 30 causing them to recoil rearward and return to their rest position until the whole process is started over again when the operator pulls the trigger.
Different barrels may be used with the projectile staging mechanism 16 to accommodate the different sized projectiles thus making the projectile staging mechanism 16 a multi-caliber system. Barrel 28 can be readily removed and replaced by a different barrel simply by unscrewing it from a barrel-retaining device 36 , which is secured to the end of front barrel support 38 . Besides threads, barrel-retaining device 36 may also be secured via an O-ring that is compressed by barrel retaining device 36 and a flange 40 on the front end of the barrel 28 .
The magazine 24 may be any commercial off the shelf device. Different magazines may be used to accommodate different sized projectiles. Such projectiles may include, but are not limited to, .177 caliber BBs, .177 caliber pellets, .25 caliber ball bearings, 6 mm airsoft rounds, and any other small caliber ammunition. The term “magazine” can also include any type of feed mechanism referred to as a “drum,” “stick magazine,” “box magazine,” “gravity feed,” or any such similar term.
Referring now to FIGS. 3A-6B , the magazine well 46 holds the magazine 24 in position to correctly present the leading projectile 35 in magazine 24 into the projectile staging mechanism 16 . Magazine well 46 not only holds the magazine 24 , but also secures or retains it in position via a magazine retaining mechanism 48 . Magazine retaining mechanism 48 provides the operator with two different options for releasing magazine 24 from the magazine well 46 . The first option removing the magazine 24 is to activate the lever 50 . Lever 50 is biased to its rest position via a compression spring 51 , which engages lever 50 in a cutout in magazine 24 and thus prevents its removal from magazine well 46 . The second option removing the magazine 24 is to push either of the magazine release buttons 52 located on either side of magazine well 46 . Magazine release buttons 52 can be captured via an hourglass shaped rod 54 that runs from either side of magazine well 46 . Magazine release buttons 52 can be biased to their rest position, i.e., the centerline of magazine well 46 , via compression springs 56 . When either of the magazine release buttons 52 are pushed hour-glass shaped rod 54 moves toward center line of magazine well 46 where the increasing diameter of the hour-glass shaped rod 54 applies a downward force onto a rearward protruding arm 58 of lever 50 . This downward force on lever 50 disengages magazine 24 from the magazine well 46 .
Referring now to FIG. 7A , a direct drive embodiment of projectile staging mechanism 16 of the invention is illustrated. All aspects of this embodiment are similar to that of projectile staging mechanism 16 in FIGS. 2 and 3A with differences noted below. The direct drive embodiment of projectile staging mechanism 16 utilizes a tube 30 like the indirect drive embodiment of projectile staging mechanism 16 ( FIG. 2 ); however, in this particular embodiment tube 30 and tube bolt adapter 32 are not biased toward bolt 18 via a recuperator spring. Instead, tube bolt adapter 32 removeably connects, by threads for example, to and moves with bolt 18 . Because tube bolt adapter 32 is connected to bolt 18 , a recuperator spring is not required. In the direct drive embodiment, the relationship between tube 30 and barrel 28 are the same as in the indirect drive embodiment of projectile staging mechanism 16 .
FIG. 7B shows the direct drive embodiment with the tube 30 brought forward by bolt 18 and slid over the rearward end of barrel 28 and over projectile inlet hole 34 to create an airtight seal therewith. FIG. 7B is similar to FIG. 3B for the indirect embodiment. FIG. 7C shows the tube 30 at its forward most position and the compressed gas pushing the projectile 35 down the barrel 28 . FIG. 7B is similar to FIG. 3C for the indirect embodiment.
The embodiments shown in FIGS. 3A and 7A , illustrate the tube 30 with a diameter smaller than barrel 28 . As such, tube 30 slides along the interior surface of barrel 28 when the paintball marker 12 is fired. As mentioned above, in other embodiments the diameter of tube 30 may be larger than the diameter of barrel 28 . In that situation, the tube 30 would slide along an exterior surface of the barrel 28 . FIGS. 8A-8C illustrate this configuration. Other than the increased diameter of the tube 30 , the structural and operational aspect of the paintball marker conversion unit 10 remain largely unchanged. As shown in FIG. 8B , the tube 30 covers up projectile inlet hole 34 of barrel 28 to create an essentially airtight seal. In addition, because the tube 30 slides along the exterior surface of the barrel 28 , the tube 30 does not contact the projectile 35 during the firing process.
While the present invention has been illustrated by a description of embodiments and while these embodiments have been described in some detail, it is not the intention of the Applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications other than those specifically mentioned herein will readily appear to those skilled in the art. | A paintball marker conversion unit includes a projectile staging mechanism and adapter. The adapter couples the projectile staging mechanism to a conventional paintball marker with a particular barrel configuration. Different adapters can be used to couple the projectile staging mechanism to different conventional paintball markers with different barrel configurations. Thus, the projectile staging mechanism may coupled with various paintball markers provided a proper adapter is utilized to match a particular barrel configuration. The paintball marker conversion unit allows a conventional paintball marker to fire projectiles other than paintballs. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. application Ser. No. 13/395,270, filed Mar. 9, 2012, which is a U.S. National Phase application under 35 U.S.C. §371 of International application PCT/US2010/048477, filed Sep. 10, 2010 which claims the benefit of U.S. Provisional Application No. 61/241,207, filed Sep. 10, 2009. The entire disclosures of all of the above applications are hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with federal government support under contract N000140910590 awarded by the Office of Naval Research. Therefore, the U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] High performance permanent magnets, those having high energy products (BH) max , when B is the magnetic induction and H is the coercive field, can be broadly classified into three categories: rare earth-3d transition metal intermetallics (e.g., Nd 2 Fe 14 B, Sm 1 Co 5 and Sm 2 Co 17 ), AlNiCo (alloys composed primarily of iron with additions of aluminum, nickel, cobalt, copper, and sometimes titanium), and ceramic magnets (typically strontium-doped barium hexaferrites). Commercial permanent magnet applications include those for exerting attractive and repelling forces (e.g., magnetic separators, latches, torque drives, and bearings), for energy conversion (e.g., magnetos, generators, alternators, eddy current brakes, motors, and actuators), for directing and shaping particle beams and electromagnetic waves (e.g., cathode ray tubes, traveling wave tubes, klystrons, cyclotrons, and ion pumps), and for providing magnetic bias fields for a wide range of rf, microwave, and mm-wave devices (e.g., isolators, circulators, phase shifters, and filters). The magnets containing rare earth elements provide the highest energy products, (BH) max , but they are expensive and prone to corrosion, and pose severe cost limitations and supply chain challenges to commercial industries. Alternatively, AlNiCo and ceramic magnets have substantially lower (BH) max values but are significantly less expensive and more readily available from many sources. For that reason, AlNiCo and ceramic ferrite have captured substantial global permanent magnet market segments. The annual revenue generated by ceramic magnets is second only to that generated by high performance magnets of Nd—Fe—B.
[0004] However, very few additional developments in viable permanent magnet materials have occurred since the development of Nd—Fe—B in the early 1980s. Similarly, AlNiCo and ceramic magnets have not experienced significant improvement in permanent magnet properties for decades.
[0005] Improvements have come, though, to carbon-containing magnetic materials, which have many potential applications such as in high-density magnetic recording media, high resistivity soft magnetic materials, magnetic toner in xerography, and as contrast agents in high resolution magnetic resonance imaging. In previous work, researchers have focused on cobalt/carbide related materials that include carbon-coated magnetic-metal nanocrystallites (Wang et al., 2003), Co—C granular films (Lee et al., 2007; Konno et al., 1999; Wang et al., 2001), M n C (M═Fe, Co, Ni, Cu, n=1-6) nanoclusters (Black et al., 2004) and Co 2 C films (Premkumar et al., 20070. In those earlier works, the focus was placed on fabrication and application of carbon-related composites. The granular magnetic films, consisting of isolated particles suspended in a nonmagnetic host, were expected to produce low noise, high density magnetic media. The so-called core-shell nanoparticles constitute another form of nanocomposite. In the 1990s, McHenry et al. (McHenry et al., 1994) reported on the magnetic properties of carbon coated cobalt nanocrystallites. These nanocrystallites were proposed for applications ranging from recording media to emerging biomedical applications in imaging and cancer remediation therapies. Additional research has included theoretical and experimental studies of M n C (M═Fe, Ni, Co, etc.) clusters (Zhang et al., 2008), which are cage-like structures of transition metal containing carbon atoms that demonstrate unusual structural and chemical stabilities.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a composition of a crystalline ferromagnetic material based upon nanoscale cobalt carbide particles and to a method of manufacturing the ferromagnetic material of the invention via a polyol reaction. The crystalline ferromagnetic cobalt carbide nanoparticles of the invention provide a rare-earth-free alternative to NdFeB and SmCo for high performance permanent magnet applications. They compete directly with AlNiCo and ceramic based permanent magnets. In addition, the processes according to the invention are extendable to other carbide phases, for example to Fe-, FeCo-carbides. Fe-and FeCo-carbides are realizable by using as precursor salts Fe-, Co-, and mixtures of Fe- and Co-salts, such as acetates, nitrates, chlorides, bromides, citrates, and sulfates, among others. The materials according to the invention include mixtures and/or admixtures of cobalt carbides, as both Co 2 C and Co 3 C phases. Mixtures may take the form of a collection of independent particles of Co 2 C and Co 3 C or as a collection of particles which consist of an intimate combination of Co 2 C and Co 3 C phases within individual particles. The relative proportions of these two phases as well as the morphology of each phase cantribute to their attractive permanent magnet properties, particularly at low temperatures through room temperature and up to over 400 K.
[0007] The cobalt carbide-based magnetic materials according to the invention are processed by chemical polyol reduction of metal salts. The precipitate of the reaction need only be rinsed and dried prior to packaging. Packaging may be in the form of isotropic or anisotropic high density compacts, bonded magnets, particle suspensions, etc. The best permanent magnet properties of the carbide particles according to the invention include room temperature coercivities as high as at least 4 kOe and room temperature saturation magnetization up to at least 70 emu/g. In the carbide particles according to the invention, the room temperature coercivity can be 500 Oc or greater, 1 kOe or greater, or 4 kOe or greater, and the room temperature saturation magnetization can be 20 emu/g or greater, 40 emu/g or greater, or 70 emu/g or greater. As increasing coercivity varies inversely with saturation magnetization, the appropriate balance of values of each of these properties for a specific application is optimized. The highest room temperature (BH) max , the primary figure of merit for permanent magnets, is > 20 KJ/m 3 for the free (i.e., not compacted) carbide powders according to the invention. (This comparison is made to other permanent magnetic free powders and not to compacted specimens.) In addition to permanent magnet applications that require high energy product, the invention allows far the synthesis of high magnetic moment, low coercivity particles that can find application as high resistivity soft magnetic materials for power conversion, generation, and conditioning; magnetic toner in xerography; and as contrast agents in high resolution magnetic resonance imaging. Alternatively, cobalt carbide particles can also be synthesized that have high coercivity to provide them utility as high-density magnetic recording media.
[0008] The crystalline ferromagnetic cobalt carbide nanoparticles of the invention may be processed into permanent magnets using methods well known to those of ordinary skill. Permanent magnets are typically used as compacted cores. These are typically uniaxially pressed, followed by sintering at elevated temperatures for prolonged times. These compacts can be prepared as isotropic compacts or as anisotropic compacts, the latter with the field being applied during alignment. Anisotropic compacts are preferred for motor and power generation applications. Some particularly preferred applications for compacts of crystalline ferromagnetic cobalt carbide nanoparticles according to the invention include traveling wave tubes (TWT) for space exploration and satellite communication, inertial devices for accelerometers and gyroscopes, power tools for medical applications, permanent magnet motors and generators for aircraft engines, high density magnetic recording and video tapes, bio-labelling and drug carrier applications, hybrid car motors, and replacement materials for toner particles.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] Other features and advantages of the invention will be apparent from the following description of the preferred embodiments thereof and from the claims, taken in conjunction with the accompanying drawings, in which:
[0010] FIG. 1 shows a representative θ-2θ x-ray diffraction scan obtained from powder particles according to the invention processed using the polyol reduction reaction according to the invention. Vertical lines correspond to the position and amplitude of diffraction peaks from JCPDS reference powder diffraction files Co 2 C (65-1457) and Co 3 C (26-0450);
[0011] FIGS. 2 a - 2 c are high-resolution transmission electron microscopy images of a representative cobalt carbide nanoparticle sample according to the invention. The insert to FIG. 2 a shows an agglomerated particle cluster about 300-500 nm in diameter. FIGS. 2 a and 2 b are TEM images of rod-like Co-carbide crystals surrounded by a thin 1 to 4 nm graphite-like layer (denoted by arrows). FIG. 2 c is an HRTEM image of a rod-like Co-carbide nanoparticle of aspect ratio near 5:1;
[0012] FIGS. 3 a - 3 c are HRTEM images of a Co 3 C nanoparticle with orientation close to the [010] zone axis. The FFT (Fast Fourier Transform) ( FIG. 3 b ) was indexed to the Co 3 C phase (space group: Pnma with a=5.03 Å, b=6.73 Å and c=4.48 Å) with additional reflections appearing due to double diffraction. A simulated diffraction pattern of Co 3 C along this zone axis is provided for comparison in FIG. 3 c . The corresponding IFFT (Inverse Fast Fourier Transform) image ( FIG. 3 d ) shows the lattice spacing of about 5 Å, consistent with a [100] direction along the long axis of the particle;
[0013] FIG. 4 a is an HRTEM image of a Co 2 C crystal (space group: Pnnm with a=4.45 Å, b=4.37 Å, and c=2.90 Å) close to the [001] zone axis. The FFT (inset to FIG. 4 a with simulated diffraction pattern in FIG. 4 b ) from a portion of the crystal shows a near-square pattern indicative of this zone in which the lattice parameters a and b are nearly equal. The (100) and (010) reflections are present due to double diffraction. The IFFT image ( FIG. 4 c ) indicates the lattice spacing of (100) and (010) is ˜4.4 Å;
[0014] FIG. 5 shows a room temperature hysteresis loop of a representative nanoparticle powder sample according to the invention having Ms of 73 emu/g and an H c of 3.1 kOe. The (BH) max is 20.7 kJ/m 3 ;
[0015] FIG. 6 shows room temperature saturation magnetization (M s ) data plotted versus coercive field (H c ) data for many nanoparticle powder samples according to the invention. Saturation magnetization values correspond to moments measured under the application of 17 kOe;
[0016] FIG. 7 shows the magnetic properties (saturation magnetization and coercivity) of a number of nanoparticle powder samples according to the invention plotted versus the phase volume ratio of the specific sample and illustrates the interrelationship among saturation magnetization, coercivity and the volume fraction of Co 2 C to Co 3 C as measured by X-ray diffraction. The plotted lines are intended as a guide to the eye. Error bars reflect the uncertainty in measured values;
[0017] FIG. 8 shows the magnetization response to temperature for a representative sample according to the invention. heated from 10 K to over 900 K. The magnetization value was determined under the application of a 10 kOe field. The solid curve is a fit to a molecular field theory approximation with T c of 510 K. At temperatures approaching 700 K, an irreversible transformation occurs. The high magnetization and Curie temperature of the sample heated above 700 K is consistent with metallic cobalt at that temperature;
[0018] FIG. 9 shows the 300 (RT) and the 10 K (low temperature) hysteresis loops of a representative nanoparticie powder samples according to the invention. At 10 K a knee is observed near remanence, indicating the decoupling of hard and soft phases. These results imply that the Co 2 C and Co 3 C phases are exchange coupled at room temperature but not at 10 K; and
[0019] FIG. 10 shows energy products (BH) max as kJ/m 3 , plotted versus intrinsic coercivity for cobalt carbide nanoparticie powders according to the invention compared with powders of AlNiCo and ceramic ferrite systems. Values of (BH) max of Co x C were calculated with corrected magnetization values as described.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The chemical synthesis methods employed herein to produce size-, shape-, composition- and phase-controlled, highly-coercive cobalt carbide nanoparticles according to the invention are based upon reduction of metallic salts in a liquid polyol medium that acts as both a solvent and a reducing agent. The reduction reaction kinetics of the process are enhanced by controlling the type, temperature, and concentration of the polyol medium and by adding appropriate surfactants that limit the re-oxidation of the reduced ions and regulate the growth of particles as the reaction progresses. The reaction takes place in the presence of a rare earth lanthanide series ion such as Sm II or another ionic form of a rare earth lanthanide series element as described herein.
[0021] In general, for the preferred embodiment crystalline Co x C nanoparticles according to the invention, the chemical synthesis method of the invention begins with the addition of a solution of a Co (II) salt (such as acetate, nitrate, chloride, bromide, citrate, and sulfate, among others) to tetraethylene glycol, with glycols of other molecular weights being equally feasible. Poly-vinylpyrrolidone (PVP, MW˜40,000) is introduced as a capping agent along with NaOH as a catalyst, with other capping agents and catalysts being equally feasible. In an exemplary procedure, the reaction takes place in the presence of Sm II . The Sm II ions are introduced as a nucleating agent, and they may also serve as an additional catalyst. The solution is allowed to degas in N 2 gas (or in some instances Ar gas) for 10-15 minutes prior to the start of the reaction. The solution is then heated to the boiling point of tetraethylene glycol (˜573 K) for 1-2 h using a distillation apparatus with magnetic stirring although mechanical stirring is equally feasible. After the completion of the reaction, the solution is cooled to room temperature, magnetically separated several times using an external rare earth magnet (with other forms of separation such as centrifugation being equally feasible), and rinsed repeatedly in methanol to remove unreacted reagents. The precipitate is dried under vacuum at room temperature prior to characterization.
[0022] The dried powders were characterized by X-ray diffraction (XRD), transmission electron microscopy (TEM), and vibrating sample magnetometry (VSM) for the determination of phase, morphology, and temperature dependent magnetic properties, respectively. XRD measurements were performed using a Rigaku-Ultima-III Bragg-Brentano diffractometer employing Cu-Kα radiation (λ=0.15418 nm) in the θ-2θ powder diffraction geometry. Thermomagnetometry was performed using a Lakeshore Cryotonics Inc. Model 7400 VSM for temperatures ranging from room temperature to 1000 K. A Quantum Design physical property measurement system (PPMS) was employed to extend the temperature studies down to 10 K. The powders were characterized using a JEOL 2200-FX high-resolution transmission electron microscope with a 200 kV accelerating voltage. Samples for TEM were prepared by dispersing a drop of nanoparticle-loaded liquid suspension onto a carbon film supported by copper mesh (400 grid mesh) followed by evaporation of the liquid medium. Fast-Fourier transforms (FFTs) and inverse-fast Fourier transforms (IFFTs) were obtained from experimental high resolution TEM images using Digitalmicrograph™ software. Energy dispersive x-ray spectroscopy (EDXS) was utilized to determine the composition of the powder particles.
[0023] The following examples are presented to illustrate the advantages of the present invention and to assist one of ordinary skill in making and using the same. These examples are not intended in any way otherwise to limit the scope of the disclosure.
I. Structure, Phase and Morphology
[0024] For structural characterization, X-ray diffraction was used for phase identification and high resolution electron microscopy with selected area diffraction was used as a means, not only to confirm phase, but also to identify particle morphology, e.g., as spheroid or acicular particles.
[0025] FIG. 1 shows a representative θ-2θ x-ray diffraction scan obtained from powders processed using the polyol reduction method according to the invention. In FIG. 1 , the data collected at room temperature from powders that were chemically processed, rinsed, and dried, is depicted with an overlay of data from JCPDS reference powder diffraction files Co 2 C (65-1457) and Co 3 C (26-0450) in which the intensity and position of each Bragg diffraction peak is represented by a vertical line. (The JCPDS databases of diffraction files are universally used by materials scientists to identify phases and their relative content in unknown material systems.)
[0026] There exist some diffraction features, for example near 67 degrees in 2θ, whose amplitude arises from residual phases that may include different allotropes of carbon and/or unreacted precursors. XRD analysis confirms that Co 2 C and Co 3 C are the dominant phases present in these nanoparticles of the invention.
[0027] FIGS. 2 a - 2 c depict high-resolution transmission electron microscopy images. TEM observations show agglomerated particle clusters, about 300-500 nm in diameter (see inset to FIG. 2 a ), consisting of nanocrystalline Co-carbide particles with acicular or rod-like morphology having an approximate 2:1 aspect ratio. The ferromagnetic nature of these particles is the driving force behind particle agglomeration. The acicular nature of the particles provides the potential for field-aligned particle compacts, i.e., anisotropic compacts, that will provide superior performance in power generation, conditioning, and conversion operations. FIGS. 2 a and 2 b are TEM images of rod-like Co-carbide crystals. These crystals are surrounded by a thin, 1 to 4 nm, graphite-like layer denoted by arrows in FIGS. 2 a and 2 b . Such a graphitic layer may form during synthesis from the reduction of precursors and surfactants and may act as a barrier that impedes crystal growth. FIG. 2 c is an HRTEM (i.e., high resolution TEM) image of a rod-like Co-carbide nanoparticle with an aspect ratio near 5:1. In order to determine the crystal structure and preferred growth directions, fast Fourier transforms (FFT) were obtained from HRTEM images of individual nanocrystalline particles.
[0028] FIG. 3 a is a HRTEM image of a Co 3 C nanoparticle with orientation close to the [010] zone axis. The FFT seen in FIG. 3 b was obtained from part of the crystal and indexed to the Co 3 C phase (space group: Pnma with a=5.03 Å, b=6.73 Å and c=4.48 Å), with additional reflections appearing due to double diffraction. A simulated diffraction pattern of Co 3 C along this zone axis is provided for comparison (see FIG. 3 c ). The corresponding inverse fast Fourier transform (IFFT) image ( FIG. 3 d ) shows the lattice spacing of about 5 Å, consistent with a [100] direction along the long axis of the particle.
[0029] FIG. 4 a shows a HRTEM image of a Co 2 C crystal (space group: Pnnm with a=4.45 Å, b=4.37 Å, and c=2.90 Å) close to the [001] zone axis. The FFT ( FIG. 4 b ) from a portion of the crystal shows a near-square pattern indicative of this zone in which the lattice parameters a and b are nearly equal. In this zone, the (100) and (010) reflections are present due to double diffraction ( FIG. 4 b ). The corresponding IFFT image ( FIG. 4 c ) shows the lattice spacing of (100) and (010) is ˜4.4 Å. Such HRTEM analyses confirm that the carbide nanoparticles of the invention have an acicular morphology, with the aspect ratio varying in relation to phase content and preparation conditions from 1.5:1 to 10:1 (and more frequently from 2:1 to 7:1), and that the crystallites are surrounded by a thin graphite-like layer.
[0030] Table I presents the phase volume ratios and lattice parameters of each phase determined by Rietveld reduction analyses of the XRD data for several samples. In addition to the these data derived from XRD analyses, similar data from selected area electron diffraction (SAED), as well as values reported in the literature from bulk standards are presented. The XRD and SAED determined lattice parameters are consistent with reported bulk values within the uncertainty of the measurements and analyses.
[0000]
TABLE I
Structural properties of cobalt carbide nanoparticle
samples according to the invention determined by X-ray
diffraction and electron diffraction measurements.
Volume
Ratio
Lattice Parameters of
Lattice Parameters of
Sample
Co 2 C:
Co 2 C (Angstrom)
Co 3 C (Angstrom)
No.
Co 3 C
a
b
c
a
b
c
Bulk
4.371
4.446
2.897
4.444
4.993
6.707
standards
SAED
4.37
4.45
2.90
4.48
5.03
6.73
4-4 (2)
1.89:1
4.361
4.446
2.888
4.448
5.005
6.718
4-4 (3)
1.06:1
4.362
4.444
2.891
4.450
5.002
6.712
4-4 (4)
0.93:1
4.365
4.443
2.894
4.454
4.998
6.714
4-4 (5)
0.99:1
4.364
4.443
2.900
4.443
5.005
6.710
4-4 (8)
1.46:1
4.361
4.444
2.890
4.454
5.004
6.707
II. Room temperature magnetic properties
[0031] FIG. 5 is a room temperature hysteresis loop curve of one cobalt carbide nanoparticle sample according to the invention. For this sample, the room temperature magnetization under an applied field of ˜17 kOe is 73 emu/g with a coercivity of 3.1 kOe. The magnetization corresponding to an applied field of 17 kOe is reported as the saturation magnetization (M s ) although it is clear that saturation was not attained and, therefore, all energy product values are underestimated. This sample has a room temperature (BH) max , of 20.7 KJ/m 3 . All magnetization values have been corrected for the presence of the nonmagnetic graphitic surface layer. (The correction involved the calculation of the surface layer volume based upon the thickness measured in HRTEM images and assuming a rectangular cross section leading to the renormalization of the magnetic moment.)
[0032] FIG. 6 presents the room temperature saturation magnetization and coercivity data for several Co x C particle samples collected during these experiments. It can be seen that there exists a great variation of property values coinciding with a broad range of chemical process parameters. Nonetheless, it is clear from FIG. 6 that there is a balance in magnetic properties—that is, the greater the saturation magnetization the lower the coercivity. These magnetic properties coincide with variations in the Co 2 C:Co 3 C volume fraction and relative particle size and morphology of each phase. The error bars presented on FIG. 6 data points represent the uncertainty in the measurement of saturation magnetization due to the ambiguity in volume and mass of the particle sample. It would be clear to one of ordinary skill that variation of reactant and solvent molar concentrations, type and concentration of nucleating agent(s), type and concentration of surfactant agents, and other factors such as reaction temperature will lead to Co 2 C:Co 3 C ratio control.
[0033] FIG. 7 is a plot illustrating how the interrelationship between saturation magnetization and coercivity corresponds to the volume fraction of Co 2 C to Co 3 C as measured by x-ray diffraction (see Table I). It can be seen that, as the relative fraction of Co 2 C increases, e.g., from 0.8 to 2.0, the magnetization value of the sample is reduced while, concurrently, the coercivity value is increased. Error bars reflect the measurement uncertainty (the error bars on coercive field values being smaller than the symbols). These results suggest the role of each carbide phase. For example, the Co 3 C phase appears to be largely responsible for high saturation magnetization values of the samples while the Co 2 C phase is responsible for large coercivity values. These results do not, however, indicate the fundamental origin of the room temperature coercivity measured in these samples. Since the particles are clearly acicular in morphology, one can conclude that dipolar or shape anisotropy is responsible for some fraction of the large coercivity value. Further, the atomic structure in these phases deviates from cubic symmetry, and, therefore, a second source of anisotropy is expected to be of a magnetocrystalline nature. Other sources of coercivity may be related to exchange between particles. Such interparticle exchange, including that of Co 2 C—Co 2 C, Co 2 C—Co 3 C, and Co 3 C—Co 3 C, may provide yet other significant contributions to anisotropy, and subsequently coercivity, in these nanoparticle carbide systems.
III. Temperature Dependent Properties of Materials
[0034] Thermomagnetic properties of a representative carbide powder sample are presented in FIGS. 8 and 9 . FIG. 8 illustrates the temperature response of magnetization for a sample heated from 10 K to 900 K. Magnetization data were collected as a function of temperature under the application of 0.5 kOe and 10 kOe fields. The data of FIG. 8 , collected under the application of a 10 kOe field, began at 10 K and approached a Curie temperature of ˜510 K. The solid curve is a fit to a molecular field approximation. At temperatures approaching 700 K, a dramatic increase in magnetization is measured. The thermal cycle reveals an irreversible transformation. The magnetization and high Curie temperature of the sample heated above 700 K is consistent with metallic cobalt. It is possible that during this vacuum heat treatment the carbide disassociates to metallic cobalt and free carbon. Having a Curie temperature near 510 K, these materials may be useful for permanent magnet applications from room temperature to greater than 400 K.
[0035] As described above, it has been established that the exemplary cobalt carbide nanoparticles according to the invention exist in two phases, namely Co 2 C and Co 3 C. The room temperature hysteresis loop of FIG. 5 illustrates a continuous variation of magnetization through remanence; behavior that is consistent with the exchange coupling of the two carbide phases. FIG. 9 contains both the 300 K and the 10 K hysteresis loops of a representative sample and clarifies this assertion. At 10 K, a knee is observed near remanence indicating the decoupling of hard and soft phases, presumably the Co 2 C and Co 3 C phases. From the trends seen in FIG. 7 , the magnetically soft phase is likely Co 3 C. These results imply that the Co 2 C and Co 3 C phases are exchange-coupled at room temperature. Whether the exchange is of a particle-particle nature, or as an intimate admixture of the two phases within a single particle, is as yet unknown.
[0036] It is also contemplated that cobalt carbide nanoparticles according to the invention, namely Co x C, can be reduced to Co x C +Co (metal) to create exchange coupled Co 2 C/Co, Co 3 C/Co, or (Co 2 C+Co 3 C)/Co nanoparticle systems. These nanoparticles would be of great value for high temperature operations and would be expected to have the same good range of coercivity and magnitization values as the Co 2 C/Co 3 C nanoparticle systems described above. A person of ordinary skill could synthesize a mixture of cobalt carbide particles and metallic cobalt (iron or iron cobalt) particles by reduction chemistry, thermal decomposition (as demonstrated in FIG. 10 ), or by direct mixing of the particles, thus forming an exchanged coupled carbide-metallic heterostructure having superior high temperature performance owing to the high Curie temperature of the metallic cobalt (iron or iron cobalt). Such magnet systems would find utility in high temperature permanent magnet applications such as stator and rotor components in turbine power generator systems, among others.
[0037] FIG. 10 displays a comparison of (BH) max vs H c among Co x C, AlNiCo and Ba/Sr ferrite ceramic magnets. AlNiCo is shown to exhibit high (BH) max , 35 kJ/m 3 , but a low intrinsic coercivity, mostly <1 kOe. Ba/Sr ferrite ceramic features high intrinsic coercivity, 3-4.5 kOe, but typical values of (BH) max , below 25 kJ/m 3 . However, the multiple-phase cobalt carbide nanoparticles of the invention demonstrate noticeable characteristics of permanent magnets, i.e., H c ˜3.5 kOe and (BH) max , ˜20 kJ/m 3 . This system has the potential to compete with both ferrite ceramic magnets and AlNiCo; the ferrite market segment in particular is second only to Nd—Fe—B. To date, the study of these cobalt carbide particles is limited to the results presented here. However, due to the existance of surface dead layers and nanomagnetic surface coatings, one would expect to see an increase in magnetization for larger Co x C particles. Therefore, it is expected that higher (BH) max values may be achieved in carbide permanent magnets with optimization of size, shape and volumetric ratio of the two phases, an optimization that is well within the skill of those of ordinary skill in the art.
REFERENCES
[0038] Black et al., 2004, J Organometallic Chemistry 689 2103-2113.
[0039] Konno et al., 1999, J Magnetism and Magnetic Materials 195 9-18.
[0040] Lee et al., 2007, J Magnetism and Magnetic Materials 310 913-915.
[0041] McHenry et al., 1994, Phys. Rev. B 49, 11358.
[0042] Premkumar et al., 2007, Chem. Mater. 19, 6206-6211.
[0043] Wang et al., 2001, Materials Science and Engineering C 16 147-151.
[0044] Wang et al., 2003, Carbon 41 1751-1758.
[0045] Zhang et al., 2008, J. Molecular Structure: THEOCHEM 863 22-27.
[0046] Zeng et al., 2007, J Magnetism and Magnetic Materials 309 160-168.
[0047] While the present invention has been described in conjunction with a preferred embodiment, one of ordinary skill, after reading the foregoing specification, will be able to effect various changes, substitutions of equivalents, and other alterations to the compositions and methods set forth herein. It is therefore intended that the protection granted by Letters Patent hereon be limited only by the definitions contained in the appended claims and equivalents thereof. | A crystalline ferromagnetic material based upon nanoscale cobalt carbide particles and a method of manufacturing the material via a polyol reaction are disclosed. The crystalline ferromagnetic cobalt carbide nanoparticles are useful for high performance permanent magnet applications. The processes are extendable to other carbide phases. Fe- and FeCo-carbides are realizable by using as precursor salts Fe-, Co-, and mixtures of Fe- and Co-salts, such as acetates, nitrates, chlorides, bromides, citrates, and sulfates. The materials include mixtures and/or admixtures of cobalt carbides, as both Co 2 C and Co 3 C phases. Mixtures may be a collection of independent particles of Co 2 C and Co 3 C or a collection of particles which consist of an intimate combination of Co 2 C and Co 3 C phases within individual particles. The relative proportions of these two phases and the morphology of each phase contribute to their permanent magnet properties, particularly at room temperature to over 400 K. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation-in-part of International Application No. PCT/EP01/12182, having an international filing date of Oct. 22, 2001, entitled, “Internal Combustion Engine With Injection of Gaseous Fuel”. International Application No. PCT/EP01/12182 claimed priority benefits, in turn, from German Patent Application No. 10052336.6 filed Oct. 22, 2002. International Application No. PCT/EP01/12182 is hereby incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The invention relates to an apparatus and method for operating a gaseous-fueled internal combustion engine that comprises a fuel injection nozzle with a nozzle disposed in a combustion chamber for injecting gaseous fuel directly into the combustion chamber. An ignition device, also disposed within the combustion chamber, is installed in close proximity to the fuel injection nozzle. The ignition device comprises a sleeve that provides a shielded space around a hot surface igniter. The sleeve restricts flow between the shielded space and the combustion chamber to prevent excessive cooling of the igniter between combustion events while allowing a combustible mixture to form within the shielded space until it ignites. The sleeve also allows pressure to build within the shielded space to a level sufficient to propel a combustion flame into the combustion chamber to ignite the charge therein.
BACKGROUND
[0003] Liquid-fueled internal combustion engines have been used to produce power and drive machines for over a century. From the beginning, internal combustion engines have undergone many improvements to become more efficient, more powerful, and/or less polluting. To assist with these improvements, fuel properties and quality have also improved, and alternative fuels such as methanol and other alcohol-based fuels have also been considered to help with reducing harmful emissions. However, compared to such liquid fuels, an equivalent amount of a combustible gaseous fuel, such as methane, hydrogen, natural gas, and blends of such fuels, with equivalence measured on an energy basis, can be combusted to produce the same power while producing less harmful emissions in the form of particulates and greenhouse gases.
[0004] However, a problem with replacing liquid fuel with such gaseous fuels in a conventional internal combustion engine has been that such gaseous fuels typically do not ignite as readily as liquid fuels. There are also many other differences that result when a gaseous fuel is substituted for a liquid fuel. For example, the combustion strategy may be different to account for longer ignition delays associated with a gaseous fuel, or a longer time may be required to inject a gaseous fuel into the engine. In addition, the fuel supply system and the manner of introducing the fuel into the engine typically require equipment specialized for handling gaseous fuels. Furthermore, the selected combustion strategy may dictate a different geometry for the combustion chamber. Accordingly, a design suitable for a liquid-fueled engine may not be suitable for a gaseous-fueled engine without considerable modifications, which can influence commercial viability.
[0005] Gaseous-fueled engines currently used in commercial vehicles operate using the Otto cycle with homogeneous mixture formation, spark ignition, and throttle control, and these engines are predominantly derived from modified diesel-cycle engines, because of the power and torque required for commercial vehicles. For example, the mixture forming process, modified from that of diesel-cycle engines, as well as the use of spark ignition, are aspects that require respective modifications of the intake system and the cylinder head. The modified combustion process also necessitates a modified combustion chamber recess in the piston. Engine manufacturers usually make efforts to keep the number of engine components that need to be modified for gaseous fuel operation as low as possible. This is an attempt to limit the additional manufacturing costs for adapting engines to use gaseous fuel, if possible, while maintaining the durability and long service life that operators of conventionally-fueled engines have become accustomed to for their commercial vehicles.
[0006] For gaseous-fueled internal combustion engines, one of the predominant combustion processes operates with stoichiometric fuel-air mixtures in combination with a three-way catalytic converter. Initially demand for gaseous-fueled engines in commercial vehicles was based on the desire for low-emission characteristics, with efficiency and fuel consumption characteristics being secondary considerations. The admixture of gaseous fuel typically takes place through a gaseous fuel mixer, arranged in the center of the intake system, with electronically controlled gaseous fuel supply. More recent gaseous fuel systems have switched to multipoint injection in front of the intake valve of each cylinder, to be able to improve equi-distribution of the mixture and to maintain a stoichiometric mixture composition during non-stationary engine operation. In order to maintain the stoichiometric (λ=1) fuel-air mixture, a ‘closed-loop’ air/fuel ratio control known from gasoline engines can be employed. The compression ratio is generally limited to values between 11:1 and 11.5:1 to ensure a sufficient safety margin against knocking.
[0007] The performance that can be achieved by non-supercharged engines with stoichiometric control is approximately 5% below that of naturally aspirated liquid-fueled diesel-cycle engines, caused by the decreased air volume drawn in by the engine, which results from the addition of the gaseous fuel into the intake pipe. Compared to today's supercharged liquid-fueled diesel-cycle engines, gaseous-fueled Otto cycle engines produce up to 15% less power, taking into account the effect of the higher thermal loads associated with Otto cycle engines. This loss in power already takes into account that the use of exhaust gas recirculation with EGR rates of up to 15% can reduce the thermal load. The only way to completely compensate for the lower performance of Otto cycle engines is to increase the displacement.
[0008] The fuel economy of stoichiometrically-controlled gaseous fuel engines is characterized by an energy consumption that is 15 to 20% higher in stationary 13 mode tests than that of comparable diesel engines. When operating frequently under low load, as is typical for buses operating in cities, the throttle control has been found to be responsible for an increase in fuel consumption of above 40%.
[0009] The disadvantages with respect to power and fuel economy of stoichiometrically-controlled gaseous-fueled engines, in comparison to today's liquid-fueled diesel cycle engines, can be significantly reduced by employing lean-mix engine concepts. Mixture formation usually takes place downstream of the turbo charger in an electronically controlled fuel-air mixer centrally located in the intake system. For compression ratios between 11:1 and 11.5:1, the lean-mix engine as a rule possesses a combustion chamber geometry similar to those of stoichiometrically-controlled engines. Since leaner natural gas fuel-air mixtures lead to a strongly decreasing rate of combustion, a suitable adjustment of, for example, the squish flow is necessary to counteract a prolonged combustion process with accordingly higher hydrocarbon emissions. Air ratios achievable by today's lean-mix engines are not higher than λ=1.5 for high engine loads and thus higher rates of combustion. At low engine loads, the combustion temperature is lower and the ability to operate on a lean mixture is thus limited to λ values between 1.1 and 1.3.
[0010] Since thermal stresses on components of lean-mix engines are lower than those in stoichiometrically-controlled gaseous fuel engines, it becomes possible to significantly increase the boost pressure, so that in combination with charge-air cooling one can achieve effective average pressures of up to 14 bar. The torque band to a large extent corresponds to that of a large number of commercially available liquid-fueled diesel-cycle engines. However, lean-mix engines still may suffer from significant power disadvantages in comparison to the power levels achieved by Euro 3 type liquid-fueled diesel cycle engines.
[0011] Since the ability to operate today's lean-mix engines on even leaner mixes is limited, especially in the lower partial load range, to λ values of 1.2 to 1.4, due to the slow rate of combustion of natural gas, these engines also require throttle control. Accordingly, the ECE R49 emission test determines fuel consumption rates that are, depending on the engine design, more than 15% higher than those of comparable liquid-fueled diesel cycle engines. For example, during everyday operation of a city bus, this results in fuel consumption values that are up to 30% higher because of the large proportion of operating time when the engine operates under idle or low load conditions.
[0012] Lean-mix concepts for natural gas engines aimed at meeting the new Euro 4 emission standards coming into effect in 2005 will be characterized by further developments of existing lean-mix engine concepts aimed at a broadening of the limits of lean-mix operation to be able to reduce NOx emission values below the limit of 3 g/kWh.
[0013] For this purpose, combustion processes are being developed that are characterized by a more intensive cylinder charging movement, to compensate for the strongly decreasing rate of combustion of very lean mixtures with a relative air/fuel ratio of up to 1.6 at operating points close to full load. Lean-mix engines of this type possess combustion processes with increased ability to run on lean mixtures and also are equipped with exhaust turbo-charging and charge-air cooling. Depending on the design, the compression ratio lies between 11.7:1 and 13:1. Such designs should be able to achieve NOx values in the ECE R49 emission test of between 1.5 g/kWh and 2 g/kWh, given hydrocarbon values upstream of the catalytic converter of approximately 2.9 g/kWh.
[0014] Due to the higher compression ratio and the lean mixture under full load, the maximum engine efficiency can be increased up to a value of 40%. Consequently, in an ECE R49 test cycle, the fuel consumption values should only be 5% to 15% higher than those of future liquid-fueled diesel cycle engine designs for the Euro 4 emission standard. Depending on the design of the turbo charger, the achievable mean pressure may reach a maximum effective mean pressure of 14 bar to 18 bar.
[0015] In addition to developments in the area of homogeneous lean-mixture processes, recent efforts have been directed to processes with high-pressure gaseous fuel injection directly into the combustion chamber of an unthrottled engine. Such engines can employ a compression ratio similar to those employed in liquid-fueled diesel cycle engines because knocking is not a problem. For example with this type of engine, a compression ratio of between 16:1 and 18:1 can be employed. An advantage of this approach is that the low emission levels achievable with a gaseous-fueled engine can be combined with the significantly higher efficiency levels normally only associated with liquid-fueled diesel-cycle engines.
[0016] U.S. Pat. No. 5,329,908 discloses a compressed natural gas injection system for gaseous-fueled engines. The fuel injection nozzle is operated so that during the injection process the gaseous fuel spreads as a cloud into the combustion chamber recess through an annular discharge opening being formed during the injection process. During this process, part of the cloud comes into contact with an ignition plug and the fuel-air mixture within the combustion chamber is ignited at the ignition plug. One of the described embodiments uses a constant pressure gas supply and a conventional glow plug serves as the ignition plug. A fuel supply unit is described for ensuring that the gaseous fuel can be supplied to the fuel injection valves with a pressure that is high enough to introduce the fuel into the combustion chamber when the piston is near top dead center. This engine operates in a high efficiency mode that achieves efficiencies like those of a liquid-fueled diesel-cycle engine. However, conventional glow plugs like those used in diesel engines are designed to provide ignition assistance only during start-up because diesel fuel readily auto-ignites at the pressures and temperatures normally present in a diesel engine once it is running. With gaseous fuels like natural gas, which do not auto-ignite as readily as diesel, with the disclosed arrangement an ignition plug may be needed to continuously provide ignition assistance to initiate combustion. Continuous activation of a conventional glow plug, which is only designed for brief use during start up, can lead to early failure. Experiments have shown that the length of a glow plug's service life generally decreases as operating temperature increases, and that conventional glow plugs can not be relied upon to provide the durability that operators of gaseous-fueled internal combustion engines are expected to demand.
[0017] U.S. Pat. No. 4,721,081 is directed towards a glow plug shield with thermal barrier coating and ignition catalyst, which purports to extend the service life of a glow plug that is used to ignite fuels that are not auto-ignitable. In the background discussion provided by the '081 patent, it is noted that it is known to provide protective tubular shields of metal or ceramic circumferentially surrounding a glow plug along its length. Further, that it is also known to protect a silicon nitride glow plug by coating the plug with a refractory metal oxide and to provide the glow plug with a combustion promoting catalyst so that the glow plug temperature may be reduced. The improvements added by the '081 patent includes a shield that has an oblique open end that exposes the glow plug in the direction of the fuel injector, while providing a solid physical barrier in the direction of the intake valves. The '081 patent further discloses coating the interior and exterior of the shield with a ceramic refractory material, such as a metal oxide that acts as a thermal barrier so that the shield reduces the cooling effect of the inlet gas on the glow plug and also reduces the electrical power needed by the glow plug to maintain a surface temperature suitable for sustaining good combustion. According to the '081 patent, to further reduce the required glow plug temperature and extend glow plug life, a combustion catalyst may be incorporated into the coating.
[0018] There is a need for a gaseous-fueled internal combustion engine that can match the performance, efficiency, reliability, and durability of an equivalent liquid-fueled diesel-cycle engine, while producing lower amounts of harmful emissions such as particulate matter and nitrogen oxides. Such an engine can play a major role in the improvement of air quality, especially in highly populated areas where presently there is concentrated use of liquid-fueled diesel-cycles engines and where gaseous fuels such as natural gas can be easily distributed.
SUMMARY
[0019] A method and apparatus is provided for injecting gaseous fuel into the combustion chamber of an unthrottled high compression engine. For example, in an engine with a compression ratio of between 16:1 and 18:1, the gaseous fuel can be injected at a high pressure of approximately 200 bar, towards the end of the compression stroke. This results in the formation of an inhomogeneous fuel-air mixture, similar to that found in a diesel engine. A high-speed gaseous fuel injection valve is employed to inject the gaseous fuel into the combustion chamber. The combustion chamber is defined by a cylinder, a piston that is reciprocable within the cylinder, and a cylinder head covering one end of the cylinder. The combustion chamber can be further defined in part by a piston bowl or recess formed in the piston head (which is the end surface of the piston that faces the combustion chamber). Using the present method and operating with a compression ratio substantially the same as that of an equivalent diesel engine, it is possible to reduce the modifications required for natural gas operation and to reduce manufacturing costs, by shaping the combustion chamber so that it corresponds largely to the geometry of combustion chambers found in conventional diesel engines.
[0020] Due to the insufficient ability of gaseous fuels such as natural gas to reliably self-ignite in an internal combustion engine, ignition of the fuel-air mixture is ensured by a method comprising:
[0021] introducing a gaseous fuel into the combustion chamber by means of a plurality of fuel sprays released into the combustion chamber from a fuel injection valve disposed within the combustion chamber;
[0022] directing one of the fuel sprays to an impingement point on a sleeve that surrounds an igniter so that a portion of the gaseous fuel flows through an intake opening provided in the sleeve, whereby the gaseous fuel mixes with air in a shielded space provided between the igniter and the sleeve to form a combustible fuel-air mixture next to the igniter;
[0023] igniting the combustible fuel-air mixture by heating a surface of the igniter to a temperature that causes ignition of the combustible fuel-air mixture; and
[0024] restricting fluid flow between the combustion chamber and the shielded space and retaining a substantial portion of the combustible fuel-air mixture within the shielded space until combustion of same increases pressure within the shielded space to a magnitude that propels a burning fuel-air mixture therefrom, through at least one discharge opening and into contact with roots of the plurality of fuel sprays in the combustion chamber near the fuel injection valve.
[0025] A preferred embodiment of the method further comprises injecting the gaseous fuel into the combustion chamber at a first flow rate when the engine is operating at low load or idle, and injecting the gaseous fuel into the combustion chamber at a second flow rate when the engine is operating at high load, wherein the second flow rate is higher than the first flow rate.
[0026] To further improve combustion stability and engine efficiency, the method can further comprise controlling the flow rate so that for expected operating conditions the desired fuel quantity of the gaseous fuel can be injected into the combustion chamber by an injection event that has a duration that is longer than an ignition delay associated with the ignition of the gaseous fuel that was directed towards the igniter at the beginning of the injection event. In this way, the duration of an injection event is controllable so that a combustible fuel-air mixture is provided near the fuel injection valve where it can be ignited by the burning fuel-air mixture propelled from the shielded space, even during low load and idle conditions. Injection timing and injection event duration are preferably controlled as a function of measured engine operating conditions and by referring to an electronic engine map.
[0027] Another preferred method comprises introducing the gaseous fuel into the combustion chamber in a plurality of injection events during a single engine cycle. For example, a first injection event can be employed to introduce a first quantity of the gaseous fuel into the combustion chamber to be ignited by the igniter, followed by at least one other injection event to introduce a second quantity of the gaseous fuel. The first and second quantities of fuel together provide a total quantity of fuel that is equal to a desired amount determined by an engine controller, with reference to an engine map. The first quantity of fuel can be determined by the engine controller to be a quantity that is sufficient to ensure that the second quantity of fuel is ignited. The timing for the first injection event is preferably governed by the desired ignition timing and the timing for the second injection event can be governed by the timing that will result in the desired combustion characteristics.
[0028] In an example of this method, an ignition quantity of fuel that represents 5% to 10% of the fuel quantity needed at full load is introduced into the combustion chamber by the first injection event. The second injection event is employed to inject a main quantity of fuel into the combustion chamber to supplement the ignition quantity of fuel to provide the amount of fuel required to satisfy the demanded engine load, as determined by the engine controller by referring to an engine map. In this example, the two separate fuel injection events can be timed to provide more intensive and thus more stable ignition of the fuel-air mixture without an increase in the surface temperature of the igniter, a prerequisite for lower emissions of carbon monoxide and unburned fuel. In addition, because some of the fuel is introduced during the first injection event, this results in a smaller ignitable mixture volume when combustion begins, which leads to a lower heat release rate and thus less combustion noise.
[0029] This method can further comprise dividing the main injection quantity into a plurality of individual injection events with the number of injection events limited only by the actuation capabilities of the fuel injection valve. With this approach one can control the spatial and time distribution of the fuel-air mixture in the combustion chamber, which can be especially advantageous for the overall combustion process as well as the surface ignition process. Preferably, and especially at the beginning of the combustion event, the burning fuel-air mixture emerging from the ignition device is propelled rapidly into the combustion chamber. During the later course of the fuel injection process, an increase of the injected fuel volume and mass, under stable combustion conditions, makes it possible to achieve a shortening of the total combustion time, which is advantageous for obtaining a high thermal efficiency.
[0030] This aspect of the method, which relates to employing a plurality of injection events, can be combined with controlling flow rate and injection event duration for additional control over the combustion process.
[0031] In preferred embodiments, the igniter is electrically heated. Another feature that can be incorporated into the present method comprises controlling the electrical heating energy delivered to the igniter depending upon the engine's operating conditions. That is, the method can further comprise controlling the temperature of the igniter as a function of a measured operating parameter of the engine. For example, when high load conditions are detected, the higher combustion chamber temperatures can provide heat to the igniter and reduce the requirements for electrical heating energy. Reducing the electrical heating energy that is delivered to the igniter under such conditions can result in a significant increase in the service life of the igniter.
[0032] On the other hand, at low engine load, with the associated lower combustion chamber temperature, and at high engine speeds and low engine load, the igniter is subject to a greater heat loss, which can be compensated for by increasing the electrical power to the igniter. If such conditions are not compensated for, misfire or longer ignition delays can result, causing among other things, lower efficiency and higher emissions of unburned fuel.
[0033] A combustion catalyst coating can also be disposed on the igniter and/or sleeve so that the igniter temperature can be reduced to increase service life and reduce power required to heat the igniter. The catalytic coating can be disposed on the sleeve or on the igniter itself.
[0034] For practicing the disclosed method an internal combustion engine that can be fueled with a combustible gaseous fuel is disclosed herein. This internal combustion engine comprises:
[0035] at least one combustion chamber defined by a cylinder, a piston reciprocable within the cylinder, and a cylinder head that covers an end of the cylinder;
[0036] an ignition device with an end disposed within the combustion chamber, the ignition device comprising an igniter that is heatable to provide a hot surface and a sleeve surrounding the igniter, the sleeve defining a shielded space between the igniter and the sleeve;
[0037] a fuel injection valve disposed within the combustion chamber, the fuel injection valve being operable to introduce the combustible gaseous fuel into the combustion chamber with a plurality of fuel sprays each released from one of a plurality of fuel injection ports, wherein one of the plurality of fuel injection ports is oriented to direct a fuel spray, referred to as an ignition fuel spray, towards an impingement point on the sleeve;
[0038] an intake opening provided through the sleeve near the impingement point connecting the shielded space to the combustion chamber whereby, when the ignition fuel spray impacts the impingement point, a portion of the combustible gaseous fuel contained within the ignition fuel spray passes through the intake opening and into the shielded space;
[0039] a discharge opening provided through the sleeve, spaced further from the impingement point than the intake opening, wherein the discharge opening is oriented to direct a burning fuel-air mixture from the shielded space and towards roots of the plurality of fuel sprays near the fuel injection valve; and
[0040] wherein the sleeve restricts flow between the shielded space and the combustion chamber so that a substantial portion of the combustible gaseous fuel is retained within the shielded space until combustion of the combustible gaseous fuel within the shielded space produces a pressure therein that is higher than the pressure within the combustion chamber and the pressure is high enough to propel the burning fuel-air mixture into the combustion chamber and into contact with the roots of the plurality of the fuel sprays.
[0041] In preferred embodiments, the engine is operable with a compression ratio up to 25:1, and more preferably between 13:1 and 25:1. An engine with a variable compression ratio can be employed to change the compression ratio based upon an operating parameter such as engine load. For example, at low loads, a higher compression ratio can be employed to increase in-cylinder temperature at the end of the compression stroke to improve the combustion process and reduce the quantity of unburned hydrocarbons exhausted from the engine. At higher loads a reduced compression ratio can be employed to allow for a reduced peak cylinder pressure and lower combustion noise. With such a method, the thermal efficiency of the engine can be increased.
[0042] The size of the fuel injection valve's fuel injection ports are determined by the flow cross section required for the implementation of full load operation. Consequently, to achieve a desired duration for the fuel injection event for stable ignition during operation at lower loads, a fuel injection valve that is operable to modulate flow rate between zero and a maximum flow rate during an injection event is needed. Accordingly, a preferred fuel injection valve comprises an actuator that can be controlled to control movement of the valve needle, and consequently flow rate through the fuel injection ports. For example an injection valve that employs a piezoelectric or magnetostrictive actuator would be suitable for this purpose. Tests have shown that adjusting the time-behavior of the injection of the main fuel quantity by varying the stroke of the valve needle during the injection process can provide a means for controlling the characteristics of the combustion process.
[0043] Known actuators for fast operation of the fuel injection valve can be employed, such as hydraulic, electromagnetic, piezoelectric, and magnetostrictive actuators. For a hydraulically actuated fuel injection valve, an electromagnetic, piezoelectric, or magnetostrictive actuator can be used to operate the hydraulic valve that controls the flow of hydraulic fluid in and out of the fuel injection valve.
[0044] An electronic controller preferably controls actuation of the fuel injection valve using electronic map control, for fuel metering, adjusting timing for the start of injection, and controlling flow rate during an injection event.
[0045] The ignition fuel spray preferably has a free length of between about 3.5 and 8 millimeters. The free length is the distance between the fuel injection port that is aimed at the ignition device and the impingement point where the ignition fuel spray impinges upon the ignition device. The preferred free length corresponds to between 5% and 10% of the diameter of the piston bowl, with lower percentages within this range being generally associated with larger piston bowl diameters and higher percentages within this range being generally associated with smaller piston bowl diameters. In a preferred embodiment, the gaseous fuel injection pressure is kept at a constant pressure between 200 and 300 bar.
[0046] The intake opening can be one of a plurality of intake openings with each intake opening positioned near the impingement point so that at least some of the combustible gaseous fuel from the ignition fuel spray that impinges upon the ignition device flows through the plurality of intake openings and into the shielded space. In preferred embodiments the impingement point is equidistant from the center of each of the intake openings. When there are two intake openings, the impingement point can be the midpoint of a straight line drawn between the centers of each of the two intake openings.
[0047] The discharge opening can be one of a plurality of discharge openings. Each one of the discharge openings is spaced further from the impingement point than the spacing between the intake opening and the impingement point. Preferably, the size of each one of the plurality of discharge openings is determined by the combined flow area required to allow a desired flow through the plurality of discharge openings during full load operating conditions. In a preferred embodiment, the combined open area is between about 0.75 and 5.0 square millimeters.
[0048] In preferred embodiments, the sleeve can be equipped with between two and ten fuel passage openings, and more preferably with four to six openings. The number of openings is chosen as a function of the piston diameter, the combustion chamber diameter, the maximum crankshaft speed, and the general operating conditions.
[0049] In a preferred embodiment, the intake opening(s) and the discharge opening(s) are provided through the same lateral surface of the sleeve and their functionality is determined by their respective spacing from the impingement point where the ignition fuel spray is aimed.
[0050] The sleeve preferably has a closed end with the intake opening(s) and the discharge opening(s) being the only means for fluid communication between the combustion chamber and the shielded space.
[0051] In a preferred embodiment, there are two intake openings and two discharge openings and each opening is round and has a diameter that is no less than 1.0 millimeter and no more than 1.2 millimeters.
[0052] The effectiveness of the ignition device depends upon the sleeve being designed for a plurality of functions that are balanced against each other. On the one hand, the sleeve functions to shield the igniter from being fully exposed to the pulsating flows of the fuel-air mixture in the combustion chamber and the cooling effects of the intake charge and the gaseous fuel that are introduced into the combustion chamber. For this function, the sleeve is preferably closed-ended and surrounds the igniter to restrict flow between a shielded space around the igniter and the combustion chamber. On the other hand, for the ignition device to function, some fluid communication is needed between the combustion chamber and the shielded space so that a sufficient quantity of gaseous fuel can enter the shielded space to form a combustible fuel-air mixture that can be ignited by coming into contact with a hot surface of the igniter. For this function, the sleeve has at least one intake opening that allows fluid communication between the combustion chamber and the shielded space. The size and position of the intake opening(s) are selected so that the portion of the ignition fuel spray that enters into the shielded space through the intake opening(s) provides substantially all the fuel that is needed to initiate combustion within the shielded space and the combustion chamber. Accordingly, the ignition device is capable of igniting a combustible fuel-air mixture that forms within the shielded space and is designed to propel a burning fuel-air mixture into the combustion chamber. The discharge opening(s) provided through the sleeve allow a burning fuel-air mixture to exit the shielded space. Because the disclosed arrangement allows the needed amount of gaseous fuel to flow into the shielded space through the intake openings, the discharge opening(s) can be sized and oriented solely for directing a burning fuel-air mixture towards predetermined spaces within the combustion chamber to ignite the rest of the gaseous fuel. The total open area provided by the intake and discharge openings is very much less than the open area provided by previously known perforated or open-ended shields. Another benefit of the disclosed sleeve is that fluid flow between the combustion chamber and the shielded space is restricted for fluids entering and exiting the shielded space. That is, once a combustible fuel-air mixture forms within the shielded space and is ignited by contacting the hot surface of the igniter, pressure can build within the shielded space. Previously known shields, which have open ends or highly perforated sleeves, do not restrict flow back into the combustion chamber to the same degree. It is believed that a benefit of the present design is that it allows higher pressures to build, which helps to propel the burning fuel-air mixture through the discharge opening(s).
[0053] In preferred embodiments, the ignition device's discharge opening(s) are oriented to direct the burning fuel-air mixture towards the roots of the plurality of fuel sprays near the fuel injection ports of the fuel injection valve where a fuel-rich combustible mixture is provided.
[0054] As described above, the ignition fuel spray is at least one of a plurality of fuel sprays and the fuel sprays that are not aimed at the ignition device are oriented to distribute gaseous fuel uniformly within the rest of the combustion chamber to mix with the intake charge and form a combustible mixture. In preferred embodiments, the nozzle for the fuel injection valve can employ between four and twelve fuel injection ports, depending upon factors such as the diameter of the combustion chamber, the swirl-amplification of the fuel-air mixture formation that is required as a function of the maximum crankshaft speed, and of the general operating conditions. For example, more injection ports are normally preferred for larger combustion chambers.
[0055] Experiments have shown that the disclosed engine design, which combines an ignition device with an ignition spray of short free length, and a high compression ratio typical of self-igniting internal combustion engines (diesel engines), enables operationally dependable, reliable and low-emission operation of an internal combustion engine. Furthermore, in comparison to known configurations, an ignition device that comprises a sleeve disposed around an igniter to provide a shielded space next to the igniter can be employed to significantly reduce the heating power supplied to the igniter.
[0056] The igniter is preferably electrically heated, such as, by way of example, a glow plug. However, the glow plug should be designed for continuous operation under the operating conditions associated with the present engine. The igniter and/or the sleeve can comprise a ceramic surface. Furthermore, a combustion catalyst can be deposited on the igniter or sleeve to lower the operating temperature needed for stable combustion.
[0057] In a preferred arrangement, the gaseous fuel injection nozzle is aligned along the center of the combustion chamber recess. This centric arrangement results in a uniformly distributed injection of the gaseous fuel into the combustion chamber recess, and is conducive to a complete mixing with the air within the intake charge. Furthermore, the centric arrangement of the gaseous fuel injection nozzle makes it possible to design the cylinder head as a three-valve or four-valve cylinder head.
[0058] In a preferred method, an ignition quantity of fuel that represents 5% to 10% of the fuel quantity needed at full load is introduced into the combustion chamber in a first injection event. A second injection event is employed to inject a main quantity of fuel into the combustion chamber to supplement the ignition quantity of fuel to provide the amount of fuel required to satisfy the demanded engine load, as determined by the engine controller by referring to an engine map. This allows the timing for the first injection event to be governed by the desired ignition timing and the timing for the second injection event to be governed by timing that can result in improved combustion characteristics. For example, the two separate fuel injection events can be timed to provide more intensive and thus more stable ignition of the fuel-air mixture without an increase in the surface temperature of the igniter, a prerequisite for lower emissions of carbon monoxide and unburned fuel. In addition, because some of the fuel is introduced during the first injection event, this results in a smaller ignitable mixture volume at the time of the beginning of combustion, which leads to a lower heat release rate and thus less combustion noise.
[0059] For precise control the injection process and to ensure that the cylinders of the internal combustion engine follow the same combustion sequence, the engine can further comprise sensors and/or electronic controllers capable of detecting the time of injection. The preferred method can employ variable flow rates, achieved by controlling the stroke of the valve needle, independent of the operating point, by monitoring the movement of one or all of the valve needles.
[0060] On account of the high ignition reliability of the fuel-air mixture that is achievable with the disclosed ignition device, the engine's exhaust gas is particularly suitable for re-circulating a controlled amount back into the engine's air intake system, using what are known as techniques for exhaust gas recirculation (“EGR”). Accordingly, in a preferred embodiment the engine further comprises an EGR system for directing into an air intake system, a portion of the exhaust gas exhausted from the combustion chamber. The recirculated exhaust gas can be cooled or uncooled before being introduced into the air intake system, depending upon the engine's operating conditions. With the disclosed method, exhaust gas recirculation rates of up to 70% can be employed to reduce nitrogen oxide emissions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] Further advantageous embodiments of the invention can be found in the description of the figures, which illustrates in more detail a preferred embodiment of the invention.
[0062] [0062]FIG. 1 shows a side view of the gaseous fuel injection nozzle and ignition device disposed within the combustion chamber;
[0063] [0063]FIG. 2 shows a detailed view of the ignition device of FIG. 1; and
[0064] [0064]FIG. 3 shows an overall schematic diagram of the fuel and hydraulic systems associated with the gaseous fuel injection valve, and the controller for these systems.
DETAILED DESCRIPTION
[0065] [0065]FIG. 1 is a partial cross-section of a gaseous-fueled internal combustion engine illustrating a preferred embodiment of a combustion chamber, which is defined by cylinder 10 , piston 12 , which is reciprocable within cylinder 10 , and cylinder head 14 , which covers the top end of cylinder 10 . Fuel injection valve 20 and ignition device 30 are mounted in cylinder head 14 with respective tips that extend into the combustion chamber. This internal combustion engine can be of an inline- or V- design with any desired number of cylinders and displacement.
[0066] Piston 12 preferably is substantially the same as the piston employed in an equivalent diesel-fueled engine, and typically comprises chamber recess 13 . A simple shape for chamber recess 13 is shown for illustrative purposes, but persons skilled in the technology will understand that other shapes can be employed. For example, smaller engines can use a re-entrant combustion chamber with a pip to promote turbulence for improved mixing. The rapid formation of a fuel-air mixture within the combustion chamber can also be supported by turbulence and swirl within the cylinder charge during a fuel injection event.
[0067] The tip of fuel injection valve 20 comprises a gaseous fuel injection nozzle with a plurality of fuel injection ports through which gaseous fuel is introduced directly into the combustion chamber. At least one of the fuel injection ports is aimed at an impingement point on ignition device 30 . In the illustrated embodiment, fuel injection valve 20 is aligned with the centerline of combustion chamber recess 13 and preferably comprises between four and twelve fuel injection ports with fuel sprays 22 from such injection ports depicted in FIG. 1 by dashed lines. One of the fuel injection ports is aimed to direct fuel spray 22 a at an impingement point on ignition device 30 .
[0068] With reference to FIG. 2, ignition device 30 comprises igniter 32 and sleeve 34 , which is disposed around igniter 32 to provide a shielded space between igniter 32 and the inner surface of sleeve 34 . In the illustrated embodiment, the shielded space comprises an annular space between igniter 32 and the interior wall of sleeve 34 and the space between the free end of igniter 32 and the closed end of sleeve 34 . Reference number 33 identifies the shielded space in FIG. 2. The impingement point is a point on the outer surface of sleeve 34 that is proximate to at least one intake opening 36 provided through sleeve 34 . Intake opening 36 allows fluid communication between shielded space 33 and the combustion chamber. In the embodiment illustrated in FIG. 2 there are two intake openings 36 . The open area and the position of intake opening(s) 36 relative to the impingement point are designed to allow an amount of gaseous fuel to enter shielded space 33 that is sufficient to ignite and cause ignition of substantially all of the gaseous fuel in the combustion chamber. Experiments have shown that the illustrated arrangement with two intake openings 36 , each with a diameter of between 1 and 1.2 millimeters, can be effective. Computational fluid dynamic analysis can be used to further study intake opening size, position and number. It is presently understood that sizing intake opening 36 too small will not allow a sufficient quantity of fuel to enter shielded space 33 , whereas sizing the intake opening too large can lead to excessive flow between shielded space 33 and the combustion chamber, which can cause excessive cooling of igniter 32 and reduce pressure build up within shielded space 33 , causing slower or less extensive penetration of the burning fuel-air mixture that is propelled into the combustion chamber.
[0069] The position of ignition device 30 in cylinder head 14 is chosen so that the fuel spray introduced through the fuel injection port possesses a free spray length of between 3.5 millimeters and 8 millimeters, or 5% to 10% of the diameter of the combustion chamber recess depending upon the size of the combustion chamber. The amount of fuel introduced into the engine depends upon operating conditions such as load, and whether the load is static or dynamic (i.e. changing). Experimental results have shown that, under expected operating conditions, the above-stated spacing between the fuel injection port and the impingement point results in a sufficient quantity of gaseous fuel entering shielded space 33 to form a combustible fuel-air mixture that comes into contact with igniter 32 . It is believed that fuel spray 22 a entrains some air as it travels towards the impingement point, but that it also mixes with air that has flowed into shielded space 33 during the engine piston's intake and compression stroke. It is also believed that directing fuel spray 22 a towards an impingement point, rather than being aimed directly at an intake opening results in improved mixing and reduced cooling effects.
[0070] When a combustible fuel-air mixture forms within shielded space 33 , it contacts the hot surface of igniter 32 , and is ignited, the pressure within shielded space 33 increases rapidly as a result of combustion and the restricted flow between shielded space 33 and the combustion chamber. This elevated pressure propels a burning fuel-air mixture into the combustion chamber through at least one discharge opening 38 . In the embodiment illustrated in FIG. 2, there are two discharge openings 38 .
[0071] Discharge opening(s) 38 are spaced apart from intake opening(s) 36 so that the discharge opening(s) can be oriented to aim the burning fuel-air mixture to other parts of the combustion chamber for efficient burning of the combustible fuel-air mixture that forms as a result of an injection event. In a preferred embodiment, discharge opening(s) 38 are aimed towards the roots of fuel sprays below the nozzle of fuel injection valve 20 . Discharge opening(s) 38 are spaced further from the impingement point than intake opening(s) 36 . Under preferred operating conditions, an injection event continues while the burning fuel-air mixture emerges from shielded space 33 , and it is believed that the spacing of the discharge opening(s) from the impingement point reduces interference between the burning fuel-air mixture that emerges from ignition device 30 and fuel spray 22 a that is directed towards ignition device 30 . Reducing such interference can help to produce a very short ignition lag, which has a positive effect on the operating characteristics of the internal combustion engine. Compared to liquid fuels, a fuel injection event with a longer duration can be required to inject a gaseous fuel. Accordingly, the arrangement of the intake and discharge openings in relation to the impingement point is important because fuel injection valve 20 can continue to inject gaseous fuel into the combustion chamber after combustion is initiated because fuel spray 22 a does not interfere significantly with the spread of the burning fuel-air mixture propelled through the discharge openings. A longer duration for a fuel injection event can be advantageous in some preferred embodiments, because then the burning fuel-air mixture can be aimed at the roots of fuel sprays that are being simultaneously injected into the combustion chamber. In such embodiments, when a single fuel injection event is employed in an engine cycle, the ignition lag can be shorter than the time duration of the corresponding injection event.
[0072] Another reason for spacing the discharge opening further from the impingement point is that this arrangement ensures that most of the fuel enters into shielded space 33 through intake opening(s) 36 , allowing some air from within shielded space 33 to be displaced back into the combustion chamber through discharge opening(s) 38 , thereby facilitating the entry of gaseous fuel into shielded space 33 through intake openings 36 at the beginning of the injection event. Accordingly, there are a number of advantages associated with the disclosed arrangement with at least one intake opening and at least one discharge opening, with the function of these openings determined by the respective spacing between the impingement point and the intake and discharge openings. As shown in the embodiment illustrated by FIG. 2, discharge openings 38 are positioned below the intake openings 36 . In this illustrated embodiment, the impingement point is preferably equi-distant from intake openings 36 and could be the mid-point between them or another location along the center axis of ignition device 30 that is closer to intake openings 36 than to discharge openings 38 .
[0073] Gaseous fuel injection valve 20 can be a hydraulically actuated valve, with the hydraulic pressure being controlled by an electromagnetic hydraulic valve. To implement pre-injection and division of the main injection into several injection steps or “pulses”, it is possible to use a hydraulically switched valve driven by a piezoelectric actuator, since such a valve possesses a sufficiently high switching frequency. Tests have shown that a hydraulically activated valve driven by a piezoelectric actuator in combination with the hydraulic operation of the gaseous fuel valve meets the requirements for switching frequency and accuracy for controlling the beginning and duration of injection.
[0074] In another embodiment, a gaseous fuel injection valve that employs a needle that is directly actuated by an electromagnetic actuator can be employed. In such a fuel injection valve hydraulic actuation fluid is not needed and the movement of the armature of the electromagnetic actuator causes a corresponding movement of the needle to open and close the fuel injection valve. A fuel injection valve with such an electromagnetic actuator can provide the necessary speed for allowing injection events with short pulse widths and more than one injection event in a single engine cycle.
[0075] In still other preferred embodiments, fuel injection valve 20 can be “directly” actuated by a piezoelectric or magnetostrictive actuator that provides the motive force for displacing a valve member to open and close fuel injection valve 20 . Such actuators can be operated with even shorter fuel injection pulse widths and can be suitable for engines that are designed to operate at higher crankshaft speeds. A further advantage of using a directly actuated injection valve is that in addition to providing the requisite speed for multiple injection pulses during a single engine cycle, piezoelectric and magnetostrictive actuators can also be controlled to enable “rate shaping” which means that the degree of displacement caused by the actuator during an injection pulse can be controlled to adjust flow rate through the fuel injection valve during a fuel injection pulse.
[0076] Ignition device 30 , shown in FIGS. 1 and 2 can employ an igniter 32 with a ceramic surface, because ceramic materials can be fabricated with the durability needed for the harsh conditions under which the ignition device operates. To further improve the stability of ignition device 30 , the shielding sleeve 34 can also be a ceramic material. A catalytic coating can also be provided on sleeve 34 , comprising platinum and/or palladium to accelerate the ignition process for improved combustion stability. The use of such a catalytic coating is especially advantageous for smaller engines, because the size of the combustion chamber normally dictates a shielded space with a smaller volume, leading to a smaller fuel volume being ignited at the hot surface; in such an engine, an ignition device without a catalytic coating could result in slower combustion and correspondingly higher hydrocarbon and carbon monoxide emissions.
[0077] The method of operating an internal combustion engine with gaseous fuel being directly injected into the combustion chamber requires a constant high fuel pressure upstream of gaseous fuel injection valve 20 . If the engine is to be used in a vehicle, it is necessary to provide an on-board high-pressure fuel supply system. FIG. 3 shows one embodiment of such a fuel system with devices for supplying a gaseous fuel and for providing hydraulic fluid for operating gaseous fuel injection valve 120 . Gaseous fuel injection valve 120 is operable by hydraulic fluid pressure , which acts upon piston 122 . Piston 122 is associated with valve needle 124 whereby movement of piston 122 causes a corresponding movement of valve needle 124 .
[0078] In a multi-cylinder internal combustion engine, a gaseous fuel injection valve is provided for each combustion chamber and common hydraulic fluid supply line 140 supplies hydraulic fluid to each one of the fuel injection valves. Hydraulic pump 142 preferably generates a pressure of 250 to 300 bar. The pressure within hydraulic fluid supply line 140 is controlled by pressure control valve 144 , and pressure accumulator 146 is filled to maintain hydraulic pressure, even after the engine has been turned off.
[0079] On the fuel side, and continuing with the example of a multi-cylinder engine as suggested in FIG. 3, gaseous fuel injection valve 120 is supplied with a gaseous fuel pressure of 200 bar through a common fuel supply line 150 that supplies fuel to each one of the gaseous fuel injection valves. The gaseous fuel is stored in fuel storage tank 152 and supplied to the fuel supply system at a pressure corresponding to the amount of gaseous fuel remaining therein. When fuel storage tank 152 is filled to maximum capacity, the pressure of the fuel delivered to the fuel supply system will be high, and as the tank is emptied, pressure within fuel storage tank 152 decreases. If gaseous fuel storage tank 152 is fully charged, for example, with a pressure of 200 bar, then controller 160 determines this from pressure transducer 162 and controller 160 considers engine operating conditions when controlling compressor 154 and pressure control device 156 to supply the needed amount of gaseous fuel to the injection valves at the desired pressure. As more gaseous fuel is removed, and the pressure is correspondingly lower, as detected by pressure transducer 162 , and controller 160 takes this into account when controlling compressor 154 and pressure control device 156 .
[0080] Controller 160 can also be programmed and wired to control the hydraulic fluid pressure in the hydraulic system by controlling hydraulic pump 142 and pressure control valve 144 , and the actuation of fuel injection valve 120 and the other fuel injection valves in a multi-cylinder engine. In the illustrated embodiment, controller 160 is wired to control solenoid valve 128 by opening or closing the hydraulic fluid drain line. When controller 160 opens control solenoid valve 128 hydraulic fluid is drained from spring chamber 127 within injection valve 120 , and the pressure of the hydraulic fluid in control chamber 126 (above spring chamber 127 ) acts to push piston 122 downwards, whereby valve needle 124 also moves downwards to open fuel injection valve 120 and inject fuel into the combustion chamber. The illustrated fuel injection valve has an outward opening needle, and those skilled in the technology will understand that an inward opening needle is also suitable, and in either case, the nozzle of the fuel injection valve is preferably provided with features for directing fuel sprays into the combustion chamber and aiming one of the fuel sprays towards an impingement point on the ignition device.
[0081] While particular elements and embodiments of the present invention have been shown and described, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art without departing from the scope of the present disclosure, particularly in light of the foregoing teachings. By way of example, a liquefied gaseous fuel supply system comprising a cryogenic storage tank, a fuel pump, a vaporizer, and associated pressure control devices could be substituted for the compressed gaseous fuel supply system shown in FIG. 3. | An internal combustion engine comprises a fuel injection nozzle disposed in a combustion chamber for injecting a gaseous fuel directly into the combustion chamber. An ignition device, also disposed within the combustion chamber, is installed in close proximity to the fuel injection nozzle. The ignition device comprises a sleeve that provides a shielded space around a hot surface igniter and the sleeve restricts flow between the shielded space and the combustion chamber. At least one inlet opening in the sleeve allows air and fuel to enter the shielded space to form a combustible mixture therein. The sleeve contains a substantial amount of the combustible mixture within the shielded space until it ignites and pressure builds within the shielded space to propel a combustion flame through at least one discharge opening and into contact with the fuel spray roots emerging from the fuel injection nozzle. The discharge opening(s) are oriented to direct the combustion flame in the direction of the fuel spray roots. | 5 |
BACKGROUND OF THE INVENTION
The present in vent ion relates to microencapsulated insecticide compositions which are stabilized against environmental degradation. The present invention more specifically relates to microencapsulated chlorpyrifos or endosulfan stabilized against degradation by visible and ultra-violet light having unexpected extended insecticidal activity while having unexpected low toxicity to non-target species.
Chlorpyrifos, which is the common name for O,O-diethyl-O-(3,5,6-trichloro-2-pyridyl)-phosphorathio- ate, is a well-known insecticide. Two major problems of this insecticide is on the one hand its ease of decomposition when exposed to the environment and the concomitant high toxicity to non-target animals. Thus, technical chlorpyrifos has a toxicity to rats (acute oral) of an LD 50 of 168 mg/kg and a toxicity to trout (acute) of an LC 50 of 0.007 mg/kg.
Endosulfan, which is the common name for 6,7,8,9,10-hexachloro-1,5-5a,9a tetryhydro-6,9-methano-2,4,3-benzodioxathipia-3-oxide, is also a well-known insecticide, with stability and toxicity problems. Its toxicity problem is most acute to non-target species such as fish and bees as the technical material has an LD 50 to non-target species such as mice of 30 mg/kg. For an EC formulation to classified as "only harmful" its LD 50 to mice must be at least 200 mg/kg. However, to reach such a toxicity, the concentration of endosulfan must be dropped to 3%, resulting in a non-economical mixture of very low activity.
The microencapsulation of pesticides and insecticides has been proposed in the prior art as a way of extending the insecticidal life of pesticides while supposedly decreasing their toxicity to non-target animals. Examples are: U.S. Pat. Nos. 2,800,458; 3,069,370 , 3,116,216, 3,137,631, 3,270,100; 3,418,250; 3,429,827; 3,577,515; 3,959,164; 4,417,916; and 4,563,212. British Patent Number 1,371,179; European Patent Publication Numbers 148,169 and 165,227; and Israel Patent Numbers 79,575 and 84,910.
Microencapsulated chlorpyrifos has been reported in European Patent Application No. 140,548. Microencapsulated endosulfan has been reported in U.S. Pat. No. 4,230,809. in neither case is there any report of the use of ultraviolet absorbers in these microencapsulated formulations.
The use of an ultraviolet absorber to protect insecticides, especially pyrethroids, has been reported in U.S. Pat. Nos. 2,168,064; 3,063,893; 3,098,000; 3,130,121; 3,264,176; 3,541,203; 3,560,613; and 3,839,561.
U.S. Pat. Nos. 4,056,610 and 4,497,793 describe the use of specific UV absorbers in microencapsulated pyrethrins. However, these require the case of U.S. Pat. No. 4,056,610--the use of a UV absorber both the outer casing and in the liquid fill.
Regardless of the disclosure in the prior art, there has not yet been offered for sale microencapsulated chlorpyrifos or endosulfan, which has both extended insecticidal activity and extremely low toxicity to non-target animals.
SUMMARY OF THE INVENTION
According to the present invention there is provided a microencapsulated chlorpyrifos or endosulfan composition comprising a polyurea shell and one or more photostable ultraviolet and visible light absorbent compounds having a log molar extinction coefficient of from about 2 to 5 with respect to radiation having wave lengths in the range of about 310 to 450 nanometers wherein said photostable ultraviolet and visible light absorbent compound does not react with the monomer used in building the polyurea shell. The result is a microencapsulated composition having unexpected long, extended insecticidal activity with high toxicity to target species and very low toxicity to non-target animals.
DETAILED DESCRIPTION OF THE INVENTION
The microencapsulated insecticidal composition of the present inventions are prepared using standard processes. Details for chlorpyrifos appear in Example 1. Details for endosulfan appear in Example 10. The percentage of the envelope--excluding the water and the polyvinyl-alcohol varies from 3% to 50%, preferably up to 30%. Similarly, the fill contains from 0.5% to 5% preferably 1% to 3%, of the photostable ultraviolet and visible light absorbent compound.
Details of the stability of chlorpyrifos are listed in Example 2. For endosulfan, it was found that it decomposed after irradiation for 100 hours at 310±5 nanometers and 475± nanometers.
The photostable ultraviolet and visible light absorbent compounds are selected from the group consisting of sterically hindered amines and dyes. The sterically hindered amines are in turn selected from the Ciba-Geigy products known by the general trade name "TINUVIN" where the preferred ones are "TINUVIN -770" and "TINUVIN -780" having the following structures and Chemical Abstract Numbers as follows: ##STR1##
These ultraviolet and visible light absorbent compound were chosen among other reasons because they did not react with the monomers that build the envelope.
The microencapsulated compositions of the invention may also optionally contain in addition to one of the "TINUVINS" dyes selected from the group consisting of Thermoplast green, Blue paste, Fluorescein, Sudan blue, Macrolex blue and Sedan III.
The microencapsulated compositions containing chlorpyrifos are listed in Table 1. Several of these compositions were studied to determine which had the longest activity against larger species, such as beetles and cockroaches, even after exposure to sunlight, (Examples 4,5 and 8) while having the lowest toxicity to non-target species, represented by mice, fish and bees (Examples 3,6 and 9). The result was that composition Numbers 14 and 15 containing chlorpyrifos were the preferred compositions, with Number 14 most preferred.
Almost all of the microencapsulated compositions of the present invention containing endosulfan gave poor toxicological results on mice. That is, in order to obtain a formulation with an LD 50 of 200 for mice the formulation would have to be very diluted; making it commercially unacceptable. However, compositions numbers 59 and 61 showed appreciably lower toxicity to non-target species at a commercially viable concentration of endosulfan, with number 61 the best. Examples 11 and 12 show the toxicity of these two formulations against the non-target species represented by mice and fish, respectively.
Thus, the present invention affords a novel microencapsulated composition containing chlorpyrifos or endosulfan, which not only can withstand relatively long exposure to sunlight, has a low toxicity to non-target species such as mice, bees and fish, while retaining commercially acceptable toxicity levels to target species such as beetles and cockroaches.
While the invention will now be described in connection with certain preferred embodiments in the following examples, it will be understood that it is not intended to limit the invention to these particular embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the scope of the invention, as defined by the appended claims. Thus, the following examples, which include preferred embodiments, will serve to illustrate the practice of this invention, it being understood that the particulars shown are by way of example and for purposes of illustrate discussions of preferred embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of procedures as well as of the principles and conceptual aspects of the invention.
EXAMPLE 1
Representative Preparation of the Microencapsulation of Chlorpyrifos
Four separate solutions: A, B, C and D were prepared as follows:
______________________________________Solution A: 1520 ml water 15.2 g polyvinylalcohol ("MOWIOL-G-4)Solution B: 720 g melted chlorpyrifos 140 g Voranate M-580 4 g "TINUVIN-770"Solution C: 360 ml water 20 g ethylene diamine 18.3 g diethylenetriamineSolution D: 14 g propylene glycol 58.4 Nonylphenol 6 mole ethoxylated (NP-6) 10 g xanthan gum______________________________________
Formation of the microcapsules is carried out by interfacial polymerization as follows:
A good emulsion of Solution B in A was made by mixing for 5 minutes in a high sheer mixer, keeping the mixture at 40° C. To this emulsion was slowly added Solution C, keeping the temperature at 40° C. The reaction mixture was cooled to 25° C. to 35° C. and the stirring was continued for 4 additional hours. Solution D was added and the mixture stirred for 15 minutes. Representative microencapsulated compositions of chlorpyrifos are listed in Table 1.
TABLE 1__________________________________________________________________________REPRESENTATIVE MICROENCAPSULATED COMPOSITIONS OF CHLORPYRIFOS isocyanates E.D.A. DETA PDA Tinuvin 770 TEPA Tinuvin P TiO.sub.2 EscalolFormulation no. types amount (g) (g) (g) (g) (g) (g) (g) (g) Water PV__________________________________________________________________________ (g) 1. ISONATE 35 6.2 5.7 -- 0.9 -- -- -- -- 360 4 M-309 2. ISONATE 35 6.2 5.7 -- -- 1 -- 360 M-302 3. ISONATE 35 -- 5.7 -- -- 9.6 -- -- 1 360 M-302 4. ISONATE 35 -- 5.7 -- 0.9 9.6 -- -- -- 360 4 M-302 5. ISONATE 35 6.2 5.7 -- 0.9 -- -- -- -- 380 3.8 M-302 6. Voranate 35 -- 5.7 7.7 0.9 -- -- -- -- 380 3.8 M-580 7. Voranate 35 6.2 5.7 -- 0.9 -- -- -- -- 380 3.8 m-220 8. HMDI 2.61 6.1 5.7 -- -- -- 1 -- -- 360 6 9. HMDI 2.61 6.2 5.7 -- -- -- -- -- 1 360 .610. TDI 27 6.2 5.7 -- -- -- 1 -- -- 360 3.611. TDI 27 6.2 5.7 -- 1 -- -- -- -- 360 3.612. TDI 27 -- 5.7 -- -- 9.6 1 -- -- 360 3.613. Voranate 35 6.2 5.7 -- -- -- 1 -- -- 360 3.6 M-58014. Vorante 35 6.2 5.7 -- 0.9 -- -- -- -- 400 4 M-58015. Voranate 280 39.7 36.8 -- 8 -- -- -- -- 3040 30.4 M-58016. Voranate 280 39.7 36.8 -- 8 -- -- -- -- 3040 30.4 M-58017. Voranate 280 39.7 36.8 -- 8 -- -- -- -- 3500 35 M-58018. Voranate 280 34.7 31.9 -- 9 -- -- -- -- 3040 30.4 M-58019. Voranate 4.4 0.62 0.58 -- 1 -- -- -- -- 380 3.8 M-58020. Voranate 35 4.2 4 -- 1 -- -- -- -- 380 3.8 M-58021. Voranate 140 20 18.3 -- 4 -- -- -- -- 1520 15.2 M-58022. Voranate 35 5.6 5.3 -- 1 -- -- -- -- 380 3.8 M-58023. Voranate 35 5.6 5.3 -- 1 -- -- -- -- 380 3.8 M-58024. Voranate 11.7 1.86 1.71 -- 1 -- -- -- -- 380 3.8 M-58025. Voranate 35 5 4.6 -- 1 -- -- -- -- 380 8 M-58026. Voranate 35 6.2 5.7 -- -- -- 1 -- -- 360 3.6 M-580__________________________________________________________________________ EDA Ethylene diamine DETA Diethylene triamine PDA Propylene diamine TEPA Tetra ethylene penta amine
EXAMPLE 2
Stability of Unprotected Chlorpyrifos to UV/Visible Light
Unprotected chlorpyrifos was irradiated by an ultraviolet/visible light lamp for 68 hours. The stability versus the wavelength of the light is summarized as follows:
______________________________________Wave Lengths Extent of Degradation______________________________________313 ± 5 Total degradation365 ± 5 Low degradation404 ± 5 Low degradation436 ± 5 Medium degradation______________________________________ .sup.a In nanometers
EXAMPLE 3
Metthod for Determining Acute Oral Toxicity with Mice
It is preferable lo use Adult males (2-2.5 months) weighing 25-30 g. A solution of the formulation was obtained by using a "Vortex" mixer for 5 min. The quantity of the solution depended on the weight of mouse. Thus, 1 ml. solution was administered for 20 g of mouse weight. The solution was introduced by using a syringe (2 ml) through the mouth into the stomach of mouse. The test was performed in 5 replications and mortality was checked after 0,5,24,72,96,120,144,168 hours. Standardized mouse food was given during the experiment. The results for three composition of the present invention are listed in Table 2 together with the data for a standard Emulsifiable Concentrate formulation of chlorpyrifos after a time of 168 hours.
TABLE 2______________________________________ID.sub.50 ON MICE OF SEVERALFORMULATIONS OF CHLORPYRIFOS LD.sub.50Formulation.sup.a Formulation ofNumber Techincal Material.sup.b 250 g/l______________________________________ 6 2250 9,00013 2250 9,00014 >2700 >10,800E.C. formulation 120 480______________________________________ .sup.a From Table 1 .sup.b mg/kg
EXAMPLE 4
Method for Determining the Susceptibility of Beetles (Tribolium castaneum and Maladera matrida to Insecticides)
This method was used to measure the levels of susceptibility of population of beetles to a given insecticide. The method was carried out in a room free from insecticide contamination. The beetles were treated and held at a temperature of 30° C. for Tribolium castaneum and 25° C. for Maladera matrida and a relative humidity above 25%. Beetles were obtained, as far as possible, from the same area, and kept in a suitable container until required; and they were given adequate and standardized food before the experiment, Adult beetles of either sex were used. Tribolium castaneum were grown on flour enriched with 1% of beer yeast. Maladera matrida were obtained from the land of the farm "Sufa" and held in the laboratory in a suitable container on the ground which was used for food. A solution of each of the different formulations and the commercial material was obtained by using a high-shear mixer for 5 min, For each formulation Whatman paper No. 41 (d=9 cm.) was dipped into the solution during mixing and put into a petri dish (d=9 cm). The filter paper for exposure time 0 was dried in the hood, and the others were taken to the roof of the laboratory and exposed to sunlight. Approximately every 5 days, 3 petri dishes were removed from the roof and 5 beetles were placed inside each dish by using an aspirator for Trillium castaneum. The experiment was performed in 3 replications and mortality was checked each replication. The results for Maladera matrida treated with various chlorpyrifos compositions are shown in Table 3.
TABLE 3______________________________________Maladera matridaTREATED WITH VARIOUS CHLORPYRIFOSMICROENCAPSULATED FORMULATIONS Percent KilledExposure.sup.a Concentration.sup.c Formulation Type.sup.bto sun ppm 14 13 6 EC.sub.45 Blank______________________________________ 0 500 100 100 100 100 0 6 86.7 100 100 53.310 80 93.3 93.3 53.317 6.7 0 33.3 0______________________________________ .sup.a In days .sup.b From Table 1 .sup.c Of chlorpyrifos
EXAMPLE 5
Method for Determining the Efficacy of Cockroaches (Germanica blatella) to Insecticides
This method measured the levels of susceptibility of a population of cockroaches to Chlorpyrifos. Cockroaches were exposed to standard chlorpyrifos residues in a petri dish and mortality was determined. From the results, the times necessary for 50% and 95% knockdown (LT 50 and LT 95 ) can be determined. Adult males were used. If it was not feasible to obtain enough males, information on susceptibility can be obtained by using females. The test was carried out in a room free of insecticidal contamination. The cockroaches were exposed to the chlorpyrifos and held at a temperature between 25° C. and 30° C. and at a relative humidity above 25%. Cockroaches were given adequate and standardized food before the experiment. Cockroaches, Germanica blatella were grown in the laboratory in containers with ready-to-serve meaty dog food.
A solution of each of the different formulations and the commercial material was obtained by using a high-shear mixer for 5 min. A solution of different concentrations was prepared. For each formulation Whatman paper N41 (d=9) was dipped into the solution during mixing and put in a petri dish (d=9). The filter paper for exposure time was dried in a hood and the others were taken to the roof of the laboratory and exposed to sunlight. Approximately every 5 days a petri dish was removed from the roof, and 5 Germanica blatella cockroaches were placed inside. To introduce 5 cockroaches into each petri dish, the cockroaches was first anaesthetized with carbon dioxide. The test was performed in 3 replications and mortality was checked. The exposure times examined were 0,5,10,15 and 20 days, approximately. Control dishes--untreated Whatman paper with 5 cockroaches after 24 h. A cockroach was considered knocked down if it fails to move on being returned to a normal posture. The results for various microencapsulated formulations of chlorpyrifos are shown in Tables 4 and 5.
The tests were carried out according to the World Health Organization Technical Report Series No. 443 Geneva 1970, pp 130-133.
TABLE 4______________________________________Germanicia blatellaTREATED WITH VARIOUS CHLORPYRIFOSMICROENCAPSULATED FORMULATIONS Percent KilledExposure Formulation Concentration (ppm)to Sun.sup.a Type.sup.b 100 200 300 400 500 Blank______________________________________0 14 100 100 100 100 100 00 13 26.7 80 100 100 1000 6 0 93.3 93.3 93.3 1000 EMPIRE.sup.c 73.3 100 100 100 1000 EW-20.sup.d 100 100 100 100 1000 EC-45.sup.e 93.3 100 100 100 100______________________________________ .sup.a Hours .sup.b From Table 1 .sup.c Dow Chemical Company microencapsulated chlorpyrifos, 200 g/l .sup.d Water based formulation of Makhteshim Chemical Works. .sup.e Standardized Emulsified Concentrate (nonmicroencapsulated) formulation of chlorpyrifos.
TABLE 5______________________________________Germanicia blatellaTREATED WITH VARIOUS CHLORPYRIFOSMICROENCAPSULATED FORMULATIONS Percent KilledExposure Formulation Concentration (ppm)to sun.sup.a Type.sup.b 25 50 100 150 200 Blank______________________________________0 14 100 100 100 100 100 00 EMPIRE.sup.c 26.7 33.3 53.3 80 1000 EC-45.sup.d 60 60 73.3 100 100______________________________________ .sup.a Hours .sup.b From Table 1 .sup.c Dow Chemicals Company microencapsulated chlorpyrifos, 200 g/l .sup.d Standardized Emulsified Concentrate (nonmicroencapsulated) formulation of chlorpyrifos.
EXAMPLE 6
Methhod for Determining Toxicity of Fish (Guppies)
All guppies require about the same basic care: water quality as close as possible to pH=7.0 (neutral); water temperature about 24°-25° C., and good strong light for least 12 hours a day (more light makes them grow faster). The test method was carried out in a room free of insecticidal contamination. Adult fish of either sex were used.
Guppies were obtained from a fish shop and kept in a suitable 16-liter aquariums (water temperature 23°-25° C.), 10 fish/aquarium, The guppies were given adequate and standardized food (Europet Basic Food) before and after the experiment. Food was withheld for 2 days before the experiment.
Solutions of formulation and commercial material were obtained by using a high-shear mixer for 5 min. Solutions 250,500,100,2000,4000,5000, μg/liter of the formulations were prepared. Mortality was checked after 3,6,24,48,72 and 96 hour. From the results, the times necessary for 50% and 95% mortality (LT 50 and LT 95 ) can be determined for each formulation. Test were carried out also on with golden orfe fish. The results are listed for golden orfe fish in Table 6.
TABLE 6______________________________________TOXICITY OF A CHLORPYRIFOSMICROENCAPSULATED FORMULATIONTO GOLDEN ORFE FISHConcentration (μg/l)of Formulation 14Percent Killed EC (μg/l).sup.b5000 2000 1000 250 50 250Time.sup.a Percent Killed______________________________________ 0 0 0 0 0 0 0 3 100 0 0 0 0 0 6 100 0 0 0 0 1024 100 30 10 0 0 1048 100 40 20 0 10 3072 100 40 20 10 10 3096 100 40 20 10 20 30______________________________________ .sup.a Hours .sup.b Standardized Emulsified Concentrate (nonmicroencapsulated) formulation of chlorpyrifos.
EXAMPLE 1
Microencapsulated Chlorpyrifos using Variations of Formulation 14 and Containing Various Concentrations of Dyes
Following the method of Example 1, one of the preferred microencapsulated formulation, Type 14 was prepared containing various different dyes. The microencapsulated formulations prepared are shown in Table 7.
TABLE 7__________________________________________________________________________VARIATIONS OF FORMULATION TYPE 14 CONTAINING VARIOUS DYES TinuvinFormulation Isocyanate EDA DETA 770 ColourNumber Type Amount (g) (g) (g) type amount (g)__________________________________________________________________________14-G Voranate 35 5.0 4.6 1 Thermoplast 1 M-580 green14-H Voranate 35 5.0 4.6 1 Blue paste 1 M-58014-I Voranate 35 5.0 4.6 1 Fluorescein 1 M-58014-J Voranate 35 5.0 4.6 1 Sudan Blue 1 M-58014-K Voranate 35 5.0 4.6 1 Macrolex 0.25 M-580 Blue14-L Voranate 35 5.0 4.6 1 Sudan III 1 M-58014-M Voranate 35 5.0 4.6 1 Sudan III 1 M-58014-N Voranate 157.5 22.3 20.7 4.5 Macrolex 1.5 M-580 Blue14-O Voranate 259 36.7 34 7.7 Macrolex 3.0 M-580 Blue14-P Voranate 140 19.8 18.4 4 Macrolex 1.6 M-580 Blue14-Q Voranate 385 54.5 50.6 11 Sudan Blue 4.4 M-58014-R Voranate 420 59.5 55.2 12 -- -- M-58014-S Voranate 385 54.5 50.6 11 Sudan Blue 4.4 M-58014-T Voranate 525 74.4 69 15 Sudan Blue 6__________________________________________________________________________
EXAMPLE 8
Following the method of Example 4, several microencapsulated formulations of chlorpyrifos were compared as to their effect against Tribolium castaneum in petri dishes after exposure to sunlight. Results are shown in Table 8.
TABLE 8__________________________________________________________________________COMPARISON OF SEVERAL ENCAPSULATED FORMULATIONS ONTRIBOLIUM CASATANEUM AFTER EXPOSURE TO SUNLIGHTCONCENTRATION 500 P.P.M.Exposureto sunFormulation typelightEC 14A 14 13 21 19 2 3 4 5 6 8 9 Penn phos.days Percent Killed Penn wall__________________________________________________________________________ 0 100 100 100 100 100 100 100 100 100 100 100 100 100 100 5 6 100 100 100 100 100 100 100 100 100 100 100 100 10010 6 100 100 100 100 100 76 20 33 26 80 100 100 2515 0 0 60 10 36 56 13 0 0 23 0 50 40 25__________________________________________________________________________ .sup.a EC
EXPERIMENT 9
Toxicity (Acute Contact and Oral LD 50 ) of Microencapsulated Chlorpyrifos to Honey Bees (Apir mellifera L.)
A. General
The study was performed with worker honey bees of about the same age, bred in a normal beekeeper's manner. For the tests, the bees were caught from the entrance hole of the hives in groups of ten with glass capture tubes, without anesthetics. During the tests, the bees were provided ad libritum with commercial ready to use syrup for honey bees as food. Stainless steel chambers (width 10 cm, height 8.5 cm, and depth 5.5 cm) served as test cages. The inner sides of the cages (except the front side) were covered with filter paper. The test cages were exposed in incubators at about 28° C., at 40 to 60% relative humidity in darkness, while being ventilated to avoid possible accumulations of pesticides vapor. The tests were performed in five dosages of microencapsulated chlorpyrifos and one solvent control with three replicates per dosage or control.
B. Contact Toxicity Test
First the test cages with the bees in it were exposed to CO 2 in an incubator to anaesthetize the test animals with CO 2 dosage chosen so that the anaesthetization was shorter that five minutes. The test substance was then applied to the anaesthetized bees; and the treated bees were then returned to the test cages and kept under test conditions for 48 hours. Five dosages of the test substances were tested in order to provide a rational base for a proper assessment of the control LD 50 of microencapsulated chlorpyrifos to honey bees. The anaesthetized bees are laid, ventral surface up, on filter paper in petri dishes. One μl drop per bee of microencapsulated chlorpyrifos in solvent was placed in the ventral thorax using a GC-syringe.
The result was an LD 50 contact of 22.1 μ/bee compared to a toxicity of 0.059 μ/bee for technical chlorpyrifos,
C. Oral Toxicity Test
Five dosages of microencapsulated chlorpyrifos in acetone were tested in order to provide a rational base for a proper assessment of the oral LD 50 to honey bees. Ten cages containing 10 bees each were prepared without food, letting the bees starve for 1 to 2 hours. Following this, 250 μl of the prepared solutions in type of Eppendorf-pipettes were hung in each cage through one of the top openings. The bees were observed as long as uptake of the solution takes place. Each bee that vomited the solution was excluded from the test. The bees were provided with normal food after the uptake of the tested solution, but at the latest after 3 hours.
The result was an LD 50 oral of 118.5 μ/bee compared to a toxicity of 0.25 μg/bee for technical chlorpyrifos.
EXAMPLE 10
Representative Preparation of the Microencapsulation of Endosulfan
Following the general method of Example 1 four solutions, A-D were prepared.
______________________________________Solution A: 380 ml water 3.8 g polyvinyl alcohol (MOWIOL-G4)Solution B: 180 g melted endosulfan 42 g Voranate M-580 1 g "TINUVIN-770" 1 g Irganox 1076Solution C: 9 g water 9.3 g tetraethylinepentamine 5.6 g Diethylene triamineSolution D: 3.5 g propylene glycol 14.6 g Nonylphenol 6 moles ethoxylated (NP-6) 2.5 g xanthan gum______________________________________
Solution A is heated to 80° C. and Solution B is added and an emulsion is made using a high sheer mixer for 1-2 minutes. Solution C is then added and the reaction mixture is stirred for an additional 4 hours keeping the temperature of the mixture at 50° C. The pH of the solution is then reduced to 7.6 by adding H 3 PO 4 , Solution D is added, and the reaction mixture stirred for 15 minutes. Representative microencapsulated composition of endosulfan are listed in Table 9 and 10.
TABLE 9__________________________________________________________________________ Nonyl- phenol 6 mole Propyl- Tetra- Propyl- ethoxy- Xan-Isocyantes Ethylene Diethylene U.V. ene- ethylene ene lated than OtherSample Quantity diamine triamine absorb- diamine pent- gly- (NP-6) gum add- Conc.NumberType (g) (g) (g) er: (g) (g) amine: (g) col: g % (g) tives a.i.__________________________________________________________________________ %31 Voranate 11.7 2.0 1.9 Tinuvin -- -- 1.2 14.6 2.7 -- 25.8M-580 77032 Voranate 11.7 -- 1.9 Active C 2.6 -- 1.5 14.6 2.7 -- --M-58033 Voranate 11.7 2.06 1.9 Active C -- -- 1.5 14.6 2.7 -- --M-58034 Voranate 11.7 -- 1.9 Active C 2.6 -- 1.5 14.6 2.7 -- --M-58035 Isonate 11.7 2.0 1.9 Tinuvin -- -- 1.5 14.5 2.7 -- --M-301 77036 Isonate 11.7 -- 1.9 Tinuvin 2.6 -- 1.5 14.6 2.7 -- --M-301 77037 Voranate 11.7 1.86 1.71 Tinuvin -- -- 1.2 14.6 2.7 -- 24M-580 77038 Voranate 11.7 1.86 1.71 Tinuvin -- -- 1.2 14.6 2.5 -- 25M-580 77039 Voranate 11.7 1.86 1.72 Tinuvin -- -- 1.2 14.6 2.5 -- 25M-580 77040 Voranate 35 5.6 5.3 Tinuvin -- -- 3.5 14.6 2.5 Ca(No.sub.3).sub.2 17M-580 77041 Voranate 35 5.6 5.2 Tinuvin -- -- 3.5 14.6 2.5 -- --M-580 77042 Voranate 35 5.6 5.3 Tinuvin -- -- 3.5 14.6 2.5 -- --M-580 77043 Voranate 35 5.6 5.3 Tinuvin -- -- -- 2.5 -- -- --M-580 77044 Voranate 35 -- 5.3 Tinuvin -- 8.69 -- 2.5 -- -- --M-580 77045 Voranate 35 -- 5.3 Tinuvin 6.9 -- -- -- 2.5 -- --M-580 77046 Isonate 35 5.6 5.3 Tinuvin -- -- 3.5 -- 2.5 -- --M-301 77047 Voranate 35 -- -- Tinuvin 6.9 8.64 7.0 14.6 2.5 -- --M-580 77048 Isonate 35 -- 5.3 Tinuvin 6.9 -- 3.5 -- 2.5 -- --M-301 77049 Voranate 18 -- 5.3 Tinuvin -- 8.64 3.5 14.6 2.5 -- --M-580 + 17 770TDI50 HMDI 26.1 5.6 5.3 Tinuvin -- -- -- 14.6 -- -- -- 77051 TDI 26.1 5.6 5.2 Tinuvin -- -- -- -- -- -- -- 77052 TDI 26.1 -- 5.7 Tinuvin 7.7 -- -- -- 2.5 -- -- 77053 HMDI 26.1 -- 5.7 Tinuvin 7.7 -- -- 14.6 -- -- --__________________________________________________________________________
TABLE 10__________________________________________________________________________ Nonyl- phenol 6 mole ethoxy-SampleIsocyanates Amines Irganox lated Xanthan %NumberType Quantity Type Quantity 1076 gr. (NP-6) gum a.i.__________________________________________________________________________54 Isonate 38.5 DETA 5.0 1 Solid -- 19.4M-342 PDA 6.8 additive55 Voranate 45.5 DETA 5.93 1 Solid -- 21.3M-580 PDA 8.06 additive56 Voranate 38.5 DETA 5.01 1 Solid -- 23.8M-580 PDA 6.857 Voranate 42 DETA 5.7 1 Solid 14.8 26.0%M-580 PDA 7.4 Liquid 2.558 Voranate 42 DETA 5.57 1 Solid 14.8 30.7%M-580 PDA 9.54 Liquid 2.559 Isonate 42 DETA 5.57 1 Solid 14.8 25.1%M-342 PDA 7.4 Liquid 2.560 Isonate 42 DETA 5.57 1 Solid 14.8 25.2%M-310 TEPA 9.3 Liquid 2.561 Isonate 42 TEPA 9.3 1 Solid 2.5 25.6%M-342 DETA 5.57 Liquid__________________________________________________________________________
EXAMPLE 11
Following the method of Example 3, the two best microencapsulated formulations of the present invention containing endosulfan were listed for their toxicity to non-target species, represented by mice. The results are shown in Table 11. This shows the lower toxicity of formulation 61 as against formulation 59.
EXAMPLE 12
Following the method of Example 6, the two best microencapsulated formulations of the present invention containing endosulfan were tested for their toxicity to non-target species, fish, compared with the non-microencapsulated EC-35 formulation. The results are shown in Table 12. This shows the lower toxicity of formulation 61 as against both formulation 59 and against the non-microencapsulated EC-35 formulations of endosulfan.
TABLE 11______________________________________THE TOXICITY TO MICE OF THETWO BEST MICROENCAPSULATEDFORMULATIONS OF ENDOSULFAN.sup.aExposure Formulation No. 59 Formulation No. 61Time in Solution concentration - mg/kgHours 33.3 50 75 112.5 33.3 50 75 112.5______________________________________ 1 0 50 50 50 0 0 0 0 3 50 50 100 100 0 20 100 100 24 50 100 -- -- 0 50 -- -- 48 50 -- -- -- 50 100 -- -- 72 50 -- -- -- 50 -- -- --168 50 -- -- -- 50 -- -- --______________________________________ .sup.a Percent mortality.
TABLE 12__________________________________________________________________________THE TOXICITY TO FISH OF THE TWO BESTMICROENCAPSULATED FORMULATIONS OF ENDOSULFAN.sup.a EC-35 Formulation No. 59 Formulation No. 61Exposure Time Solution concentration - mg/lin hours 1 5 10 2.5 5 8 16 50 100 2.5 5 8 16 50 100__________________________________________________________________________ 3 0 0 30 0 0 0 0 0 0 0 0 0 0 0 0 6 0 0 30 0 0 0 10 10 0 0 0 0 0 0 024 0 57 70 0 20 20 40 43 100 0 0 0 0 20 5048 0 57 100 0 20 30 40 71 -- 0 0 30 30 30 10072 0 57 -- 0 20 30 40 71 -- 0 0 30 30 40 --96 0 57 -- 0 20 30 40 71 -- 0 0 30 30 40 --__________________________________________________________________________ .sup.a Percent mortality. | The present invention relates to a microencapsulated chlorpyrifos or endosulfan composition comprising a polyurea shell and one or more photostable ultraviolet and visible light absorbent compound having a log molar extinction coefficient of from about 2 to 5 with respect to radiation having wave lengths in the range of about 310 to 450 nanometers, wherein said photostable ultraviolet and visible light absorbent compound does not react with the monomer used in building the polyurea shell. The result is a microencapsulated composition having unexpected long, extended insecticidal activity with high toxicity to target species and very low toxicity to non-target animals. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to German Patent Application 10 2009 052 151.8 filed on Nov. 6, 2009 and PCT/EP2010/006723 filed on Nov. 4, 2010, which are hereby incorporated by reference in their entireties.
TECHNICAL FIELD
The present disclosure concerns a cooling system for an internal combustion engine. Furthermore, the disclosure concerns a combustion engine according to claim 9 .
BACKGROUND
Combustion engines are used in many fields, among them, for example the field of vehicle technology. Besides combustion engines that have a cylinder bank, combustion engines are also known wherein two cylinder banks are arranged in a V-shape pattern to each other (so-called V-motors). In order to be able to avoid damage to the combustion engine of a vehicle by overheating, these generally have a cooling system through which coolant flows and which provides temperature control for the combustion engine, and if applicable, also for additional vehicle components, such as a passenger compartment. For cylinder banks arranged in V-shape pattern, a coolant flows through the cylinder banks, each in parallel, and they are thereby cooled.
A significant issue in the field of vehicle manufacturing is presented in a vehicle's emission values. An important role for good emission values, besides an air-fuel ratio that is adjusted correctly and optimally for each operating situation, is also attributed to the fact that the combustion process should be as steady as possible in the same marginal conditions. One of the marginal conditions that play a role in the exhaust gas quality is an even and possibly steady temperature control or cooling of the motor or the individual cylinder banks of a combustion engine.
Another improvement of the emission values can be achieved by so-called exhaust gas heat exchangers, wherein a part of the exhaust gas from combustion engines is cooled before it is mixed into the air that is aspired by the combustion engine and led into the combustion process once again. A heat exchanger as well requires possibly steady marginal conditions, especially steady marginal conditions regarding the cooling of the exhaust gas, in order to be able to influence the emission values to the desired extent.
Besides the aforestated components, the combustion engines in the state of the art, however also have additional equipment, which requires at least a temporary cooling. As an example for such, the document DE 10 2006 012 847 A1 should be mentioned, disclosing a device for heating a cooling circuit of a combustion engine, wherein a retarder is connected to the drive of the combustion engine and wherein exhaust heat of the retarder is at least temporarily fed into a cooling circuit. The retarder comprises a fixed stator and a rotor that is movable relative to the stator, while the rotor is connected with the drive of the combustion. Both the stator as well as the rotor has paddle wheels. When the vehicle's combustion engine is in motion, so will be the rotor of the retarder. As soon as a fluid is led into the retarder housing, the rotor will set the fluid in rotation and press it against the paddle wheels of the stator, whereby kinetic energy is converted to heat and the vehicle brakes. Oils, but also water or the coolant flowing through the cooling system of the combustion engine come into consideration as fluids that can be led into the retarder housing.
A purpose of present disclosure is to provide a cooling system for a combustion engine with at least two cylinder banks, which ensures a possibly even temperature control or cooling of the individual cylinder banks and an identical number of exhaust gas heat exchanger as the number of cylinder banks, whose temperature also has to be controlled, while at the same time also other coolant consumers can be supplied reliably. It is furthermore a purpose of present disclosure to provide an appropriate combustion engine.
This purpose is fulfilled by the cooling system with the characteristics of Claim 1 . Regarding the combustion engine, the purpose is fulfilled by a combustion engine with the characteristics of Patent Claim 9 .
SUMMARY
A cooling system, through which fluid serving as coolant flows in a preferred flow direction (flow direction during operation of the combustion engine), comprises a cooling system's primary section and an identical number of cooling system secondary sections as the number of cylinder banks and the exhaust air heat exchangers of the combustion engine's CI motor. The cooling system's branch sections each have one cylinder branch section, one branch section for the exhaust gas heat exchanger, and a merging branch section. The cooling system's primary section ends in the cylinder bank branch sections, which each have one outlet for the cylinder bank's branch section, which can be provided for possible contact with fluid by a cylinder bank inlet. The exhaust air exchanger's branch sections each have a branch section inlet for the exhaust gas heat exchanger and a branch section outlet for the exhaust heat exchanger, each of which can be provided with a designated cylinder bank outlet and a designated inlet of the exhaust air heat exchanger for possible contact with fluid. The merging branch sections each have one merging branch section inlet, which can be respectively provided with a designated outlet for the exhaust gas heat exchanger for possible contact with fluid. The merging branch sections are furthermore in contact with the fluid in the preferred flow direction in downstream of the merger inlets for the merging branch sections with the cooling system's primary section, or they end in it, meanwhile a connection device is provided for a retarder in the cooling system's primary section (a retarder flow-line connection and a retarder feedback connection.)
Thereby that the connection device for the retarder is intended in the cooling system's primary section, the retarder can be supplied with the total coolant flow, while the components that are responsible for the emission values and which are to be cooled can be supplied with partial coolant flows that are as steady as possible. A hook-up of a connected retarder additionally also only minimally affects the coolant's even distribution in the cooling system's branch sections, since the flows occur in the cooling system's primary section and the flow conditions in the coolant's branch sections are thus not affected differently. By this method an even cooling of the components that are relevant for exhaust gas is ensured.
Additional characteristics and advantages of the disclosure are shown in the following description of possible embodiments of the disclosure, by means of the enclosed drawing showing the details that are relevant for the disclosure and in the claims. The individual characteristics can each be embodied by themselves or in several optional combinations in a variant of the disclosure.
A possible embodiment of the disclosure is explained in more detail in the following by means of the enclosed drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 as an example for a possible embodiment of the disclosure's cooling system, implemented in an exemplified embodiment of a combustion engine.
DETAILED DESCRIPTION
The schematic design of a possible embodiment of the disclosure's cooling system is shown as example in FIG. 1 and is presented schematically in interaction with a combustion engine 10 .
The combustion engine 10 has a compression ignition (CI) motor 12 (hereinafter also referred to as motor 12 ) with a first and second cylinder bank 14 , 16 , whereas alternatively also motors with more than two cylinder banks could be feasible. The motor 10 described as an example is a motor wherein the two cylinder banks 14 , 16 are arranged in a V-shape pattern to each other (V-motor) while also motors with other cylinder bank design could be feasible (e.g. in-line motors sectioned in several in-line cylinder banks etc.) Besides motor 12 , the combustion engine 10 furthermore has a first and a second exhaust air heat exchanger 18 , 20 , which are both components of an exhaust air cooler (not shown.)
The first exhaust air exchanger 18 is attributed to the first cylinder bank 14 and serves for the cooling of a part (preferably 30% to 40%) of the exhaust gas created in the first cylinder bank 14 , while the second exhaust gas heat exchanger 20 is attributed to the second cylinder bank 16 and cools part of the exhaust gas (preferably 30% to 40%) that is created there. The cooled parts of the exhaust gas are subsequently led into an additional combustion process through an air inlet of motor 12 , whereby the emission values of motor 12 or combustion engine 10 are affected positively.
For cooling of the two cylinder banks 14 , 16 , channels or material recesses are provided on the cylinder banks 14 , 16 through which a coolant flows during the operation of combustion engine 10 . In the described embodiment, the channels or material recesses, which function as motor heat exchangers, are integral components of the motor 12 . In alternative to these, however, also motor heat exchangers are feasible, which comprise an independent device and might possibly not be attributed to the motor 12 , but instead to the cooling system of the combustion engine 10 .
When combustion engine 10 is in operation, a coolant flows through both cylinder banks 14 , 16 for cooling of motor 12 (in a preferred operating flow direction, indicated by arrows 21 .) For this purpose, the first cylinder bank 14 is supplied evenly with coolant through a first cylinder bank's branch section 22 and the second cylinder bank 16 through a second cylinder bank's branch section 24 that is attributed to it in the cooling system for the combustion engine 10 .
The two cylinder bank branch sections 22 , 24 of the cooling system are for this purpose in contact with fluid by means of the respectively designated first cylinder bank 14 , 16 through a first cylinder bank inlet 26 , which is arranged on the first cylinder bank 14 , and through a second cylinder bank inlet 28 , which is arranged on the second cylinder bank 16 , and through corresponding branch section outlets of the cylinder banks (not shown) that are arranged on the cylinder bank branch sections 22 , 24 . For this purpose, a first cylinder bank connection device (not shown) is provided on the first cylinder inlet 26 and a second cylinder bank connection device (not shown either) on the second cylinder bank inlet 28 . The two cylinder bank branch sections 22 , 24 are supplied with coolant by a cooling system's primary section 30 , which ends in the two cylinder bank branch sections 22 , 24 upstream (relative to the preferred flow direction) from the motor 10 .
The two exhaust gas heat exchangers 18 , 20 as well must be appropriately cooled during the operation of the combustion engine 10 . For this purpose, the first exhaust gas heat exchanger 18 has a first exhaust heat exchanger inlet 32 and the second exhaust gas heat exchanger 20 has a second exhaust gas heat exchanger inlet 34 . The first exhaust gas heat exchanger 18 is supplied with coolant through a first branch section of the exhaust gas heat exchanger 36 of the cooling system, which (through a exhaust gas heat exchanger's branch section inlet) is in contact with fluid by a cylinder bank outlet 31 and (through a branch section outlet of the exhaust gas heat exchanger designated for it) by the first inlet 32 of the exhaust gas heat exchanger, meanwhile the second exhaust gas heat exchanger 20 is supplied with coolant through a first branch section of the exhaust gas heat exchanger 38 of the cooling system, which (again through a branch section inlet of the exhaust gas heat exchanger) is in contact with fluid by a second cylinder bank outlet 33 and (through a branch section outlet of the exhaust gas heat exchanger designated for it) by the first inlet 34 of the exhaust gas heat exchanger.
For outflow of the coolant, the first exhaust gas heat exchanger 18 has a first exhaust gas heat exchanger outlet 40 and the second exhaust gas heat exchanger 20 has a second exhaust gas heat exchanger outlet 42 . The first exhaust gas heat exchanger 18 is in contact with fluid through the first exhaust gas heat exchanger outlet 40 designated for it with a first merging branch section 44 of the cooling system (through an inlet for the merging branch section that is designated for it), meanwhile the second exhaust gas heat exchanger 20 is in contact with fluid through the second exhaust gas heat exchanger outlet 42 designated for it with a second merging branch section 46 of the cooling system (through an inlet for the merging branch section that is designated for it.)
Both merging branch sections 44 , 46 end downstream from the exhaust gas heat exchanger outlets 40 , 42 in a merge point or merge section 48 in the cooling system's primary section 30 . Serving for purposes of merging the two coolant flows 21 a , 21 b in the described embodiment is, e.g. a connecting pipe 50 , which is component of the second merging branch section 46 . The merging of the partial flows takes place in a coolant elbow 52 , which merges coolant partial flows 21 a , 21 b in the cooling system's primary section 30 .
Furthermore the described embodiment of a combustion engine 10 is comprised of a coolant pump 54 for agitation of the coolant and of an oil heat exchanger 56 for temperature control of motor oils, which serves as grease for the motor 12 . The coolant pump 54 is in contact with fluid with the coolant primary section 30 through a coolant pump inlet 58 that is designated for it, as well as through a coolant pump outlet 60 . The same applies to the oil heat exchanger 56 , which is in contact with fluid by the coolant primary section 30 through an oil heat exchanger inlet 62 and an oil heat exchanger outlet 64 . Both components 54 , 56 are arranged downstream from the merger section 48 .
Arranged downstream from the merge point 48 and thus downstream from the coolant elbow 52 , however upstream from coolant pump 54 are a retard inlet connection 66 in the cooling system's primary section 30 and a retard outlet connection 68 , which are in contact with fluid in the described embodiment by a retard inlet 70 or a retard outlet 72 of a retarder 74 that are arranged in the combustion engine.
It is ensured by the design in this location (downstream from the merge section 48 ) that the retarder 74 connected to retarder inlet connection 66 and retarder outlet connection 68 has the entire coolant flow available on the one hand and on the other hand it is ensured that the flow conditions in the two partial coolant flows 21 a , 21 b are not affected unevenly by an extraction of coolant by the retarder inlet connection 66 , which would lead to an unintended worsening of the emission values, since the two cylinder banks 14 , 16 and the two exhaust gas heat exchangers 18 , 20 would receive different cooling. Such would entail that the exhaust gas to be cooled by the exhaust gas heat exchangers 18 , 20 and which is to be led back to combustion (approx. 30% to 40% of the total exhaust gas) would have an undesired temperature and possibly also an undesired composition (in case of differing cooling of cylinder banks.)
Furthermore, a thermostat 76 is arranged in the cooling system's primary section 30 , which, depending on the prevalent temperature in the coolant, the coolant flow into a bypass 78 of the cooling system's primary section (which together with the other aforementioned components defines a so-called small cooling circuit), and thus directly leads to the coolant pump 54 or to a cooling outlet 80 of the cooling system's primary section 30 , which is in contact with fluid through a motor oil cooler 82 and a hot-circuit radiator 84 for cooling the coolant (so-called large cooling circuit.) For this purpose the motor oil coolers 82 and the hot-circuit radiator 84 comprise corresponding coolant inlets and coolant outlets that are in contact with fluid by the appropriate connection devices of the cooling system's primary section 30 . In flowing through the large cooling circuit, the coolant is led through a coolant inlet 86 of the cooling system's primary section 30 to the coolant pump 54 .
Both the cooling system's primary section 30 as well as the cooling system's branch sections are implemented by means of pipes in the present described embodiment; alternatively e.g. hoses are also feasible for this purpose. It should be noted at this juncture that the cooling system in its simplest embodiment merely comprises the cooling system's primary section 30 and the cooling system's branch sections, whereas all other mentioned components can be components (as applies, also integral components) of the combustion engine 10 . In alternative, the components mentioned above and in the subclaims, can also be components (as applies, integral component) of the cooling system. The inventive step however is already realized in the simplest embodiment and the technical solution is thereby defined accordingly.
Although the disclosure is described by means of an embodiment with a fixed combination of characteristics, it nonetheless also includes the feasible additional advantageous combinations as they are presented in particular, yet not exhaustively, by the subclaims. All characteristics disclosed in the application documents are claimed as relevant to the disclosure, insofar as they are new, individually or in combination, compared to the state of the art. | The invention relates to the cooling system of an internal combustion engine ( 10 ) which comprises a combustion engine ( 12 ) having at least two cylinder banks ( 14, 16 ) and a number of exhaust gas exchangers ( 18, 20 ) identical to the number of cylinder banks, as well as a retarder connection, wherein the cooling system can be flown through by a fluid serving as coolant in a preferred flow direction and comprises a cooling system trunk section ( 30 ) and a number of cooling system branch sections identical to the number of the cylinder banks ( 14, 16 ) of the combustion engine ( 12 ), said cooling system branch sections comprising each a cylinder bank branch section ( 22, 24 ), an exhaust gas exchanger branch section ( 36, 38 ) and a combining branch section ( 44, 46 ). The invention further relates to an internal combustion engine ( 10 ) corresponding thereto. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to chemical optimisation of a molten salt fuel for a fission reactor.
BACKGROUND
[0002] Nuclear fission reactors using fissile fuels in the form of molten halide salts have many advantages over solid fuelled reactors but generally suffer from problems due to continuous changes in the chemical composition of the molten fuel salt during operation as fission products accumulate and a net release of halogen from the actinide tri or tetrahalide fuel occurs. Most designs of molten salt reactors incorporate a continuous chemical treatment process in the fuel circulation to manage this problem, however doing so involves adding complex chemical engineering systems into a highly radioactive environment.
[0003] A much simpler design of molten salt reactor was described in GB 2508537 in which the fuel salt was held in static tubes in which convection or other mixing processes allowed heat to pass from the fuel salt to the tube wall at a sufficient rate for the reactor to have a practical energy production. Such static fuel tubes do not permit continuous active adjustment of the chemistry of the fuel salt. In GB 2508537 it was suggested that inclusion of metals such as niobium, titanium or nickel in the fuel salt or on the fuel tube would be useful in scavenging excess halogen released during fission but no specific suggestions were made for controlling deleterious effects of fission products.
SUMMARY
[0004] According to an aspect of the present invention, there is provided use in a nuclear fission reactor of a sacrificial metal in a molten salt fuel containing actinide halides in order to maintain a predefined ratio of actinide trihalide to actinide tetrahalide without reducing actinide trihalide to actinide metal.
[0005] According to a further aspect of the present invention, there is provided a method of maintaining oxidation state of a molten salt containing actinide halides. The method comprises contacting the molten salt continuously with a sacrificial metal, the sacrificial metal being selected in order to maintain a predefined ratio of actinide trihalide to actinide tetrahalide without reducing actinide trihalide to actinide metal.
[0006] According to a further aspect of the present invention, there is provided a fuel tube for use in a nuclear fission reactor. The fuel tube is configured to contain a molten salt comprising actinide halides. The fuel tube comprises a sacrificial metal such that in use the sacrificial metal is in contact with the molten salt, or with liquid condensed from vapour evolved from the molten salt. The sacrificial metal is selected in order to maintain a predefined ratio of actinide trihalide to actinide tetrahalide without reducing actinide trihalide to actinide metal.
[0007] According to a further aspect of the present invention, there is provided a method of managing gas production in a fission reactor comprising fuel tubes containing a molten salt fissile fuel. The method comprises contacting the molten salt fissile fuel with a sacrificial metal. The sacrificial metal is selected in order to control a level of volatile iodine compounds released from the molten salt. The method further comprises permitting gasses produced during fission of the molten salt fissile fuel to pass out from the fuel tubes into a coolant surrounding the fuel tube or into a gas space in contact with the coolant.
[0008] Further aspects are set out in claim 2 et seq.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Some preferred embodiments will now be described by way of example only and with reference to the accompanying drawings, in which:
[0010] FIG. 1 shows examples of fuel tubes containing molten fuel salt;
[0011] FIG. 2 shows examples of three methods to allow fission gas emission from fuel tubes.
DETAILED DESCRIPTION
[0012] A systematic analysis of the effects of incorporating sacrificial metals into the fuel salt or fuel tube has been carried out resulting in the identification of particularly effective metals for this purpose. Three factors dictate the suitability of any particular sacrificial metal. These are
maintaining a low redox state and hence low metal corrosive power and low concentration of actinide tetrahalides as indicated by a high ratio of trivalent to tetravalent actinides in the molten salt while not reducing actinide (usually uranium) halides to the metal form at temperatures approaching the boiling point of the salt mixture chemically binding potentially volatile fission products in the molten salt and preventing their entering the gaseous phase above the salt. Particularly important is to minimise volatile iodine compounds especially Tel 2 . Converting reactive tellurium to stable tellurides to prevent tellurium induced embrittlement of metals, especially nickel alloys, in contact with the molten salt
[0016] Thermodynamic calculations of these three factors have been carried out using a software program HSC Chemistry 7. The results are shown in Table 1.
[0017] The parameters of the thermodynamic calculation were as follows. The sacrificial metal was provided as a separate pure metallic phase in excess over other reactants.
[0000]
Salt composition in moles:
NaCl
428
UCl 3
225
UCl 4
10
Cd
0.38
I
0.84
In
0.04
Sb
0.14
Se
0.24
Te
1.47
[0018] This represents a typical fuel salt towards the end of its useful life in a fast spectrum nuclear reactor. The group 1 and 2 metals, lanthanides, noble metals and noble gasses have been excluded as they were shown to have no effect on the chemistry involved. Gas composition was determined at 600° C. and reduction of uranium to the metal at 1500° C.
[0019] Examination of table 1 indicates that zirconium, titanium, niobium, vanadium, zinc, chromium, silver and manganese are suitable as sacrificial metals to control redox state without producing uranium metal in situations where control of volatile species is not important.
[0020] Where, in addition, control of dangerous volatile species such as iodine is important then only zirconium, titanium, vanadium, chromium and silver are useful. These same metals with the exception of vanadium are also effective in controlling tellurium levels.
[0021] Silver as a sacrificial metal appears to have unique properties. Despite its high Pauling electronegativity, it is very effective at reducing UCl 4 concentrations, reducing volatile iodine species and scavenging tellurium. The high affinity for iodine is a known property of silver but the efficacy in reducing UCl 4 to UCl 3 is unexpected.
[0022] Combinations of multiple sacrificial metals produce still more favourable results where particular sacrificial metals are more effective against the three factors set out above.
[0023] While data has been presented for chloride salts, the same principles and useful sacrificial metals can be applied to fluoride salt systems.
[0024] While passive control of molten salt chemistry with sacrificial metals is of general value for molten salt reactors, it is particularly important for reactors such as that described in GB 2508537 where access to the molten salt for active management of the chemistry, for example by adding small amounts of reactive metals, is challenging. In such a reactor it is useful for the sacrificial metal to be applied to the vessel containing the molten fuel salt both above and below the level of the salt. This prevents occlusion of the sacrificial metal by deposited noble metal fission product. It can also be advantageous, particularly where the sacrificial metal has a significant neutron absorption, for the sacrificial metal not to be located near the centre of the reactor core so that any neutron absorption is minimised.
[0025] The sacrificial metal can be provided in a variety of ways. FIGS. 1 a to 1 e show examples of fuel tubes incorporating sacrificial metal. FIG. 1 a shows a fuel tube 101 a containing molten salt 103 a and an internal coating 102 a of the sacrificial metal applied to the inner wall of the fuel tube. The sacrificial metal can be applied to the inner wall of the fuel tube by a variety of methods including, but not restricted to, electroplating, plasma spraying, dipping into molten metal, brazing, welding, chemical vapour deposition, sputtering, vacuum deposition, conversion coating, spraying, physical coating and spin coating. Alternatively, as shown in FIG. 1 b, the internal coating 105 b may be applied to only part of the fuel tube 101 b, provided that part is in contact with the fuel salt 103 b. FIG. 1 c shows a further embodiment, in which a metal insert 104 c made from or coated with the sacrificial metal is placed within the molten salt 103 c inside the fuel tube 101 c. This insert may be shaped so as to aid the convective mixing of the fuel salt, e.g. spiral shaped. FIG. 1 d shows a yet further embodiment, where the sacrificial metal is provided as particles 107 d suspended in the molten salt 103 d within the fuel tube 101 d, or as coatings on such particles. FIG. 1 e shows an embodiment where the sacrificial metal is provided as particles 106 e which are allowed to sink in the fuel salt 103 e to the bottom of the fuel tube 101 e.
[0026] Use of a sacrificial metal such as titanium, vanadium, chromium or silver reduces the vapour pressure of many radioactive species produced by the fuel salt to very low levels. This makes possible much simpler methods to manage the gasses released from the fuel which, with suitable sacrificial metals present, are predominantly the noble gasses, xenon and krypton, cadmium and zirconium halides although the concentration of the latter is substantially reduced if zirconium is used as the sacrificial metal.
[0027] Accumulation of these gasses in fuel elements is a major limitation in the longevity of such fuel elements as if the gas is permitted to accumulate it generates high pressures which can rupture the cladding of the fuel elements.
[0028] It is known that, particularly in sodium cooled fast reactors, fission gasses can be allowed to vent from the fuel elements into the sodium coolant. This practice was used in the early days of development of such reactors but was abandoned because of the presence of highly radioactive, relatively long half life, cesium in the vented gas. The cesium contaminated the sodium coolant and made disposal of the sodium extremely challenging as well as creating a major hazard in the event of a sodium fire. The practice was therefore discontinued. Similar venting procedures have never been suggested for reactors other than sodium cooled reactors.
[0029] Molten salt reactors are unique in not accumulating cesium in the form of the volatile metal, which is released as a gas from metallic nuclear fuel elements and accumulated in partially leaking high pressure gas microbubbles in ceramic nuclear fuel elements. In molten salt reactors the cesium forms non-volatile cesium halide which has negligible vapour pressure at the temperatures involved. It is therefore possible to vent fission gas from molten salt reactors into the coolant without causing serious levels of contamination. This is particularly relevant for the molten salt reactor design described in GB 2508537 where the alternative is a relatively complex pipework arrangement to collect the gasses.
[0030] The gasses released in this way still contain appreciable quantities of radioactive iodine but of short half life. The radioactive iodine will contaminate the coolant but will decay to harmless levels in a relatively short time period. However, inclusion of a sacrificial metal such as magnesium, zirconium, scandium, titanium, manganese, aluminium, vanadium, chromium and/or silver reduces the amount of volatile iodine to a lower level. There is thus a major advantage to combining the use of sacrificial metals as described above with a gas venting system for the fuel tubes. Suitable gas venting systems are described in the literature (ORNL-NSIC-37, Fission Product release and transport in liquid metal fast breeder reactors) and include “diving bell” apparatus, narrow or capillary tubing and gas permeable sinters located above level of the fuel salt. The gas can be vented into the gas space above the coolant salt or directly into the coolant salt where it will bubble to the surface.
[0031] FIG. 2 a to c shows examples of three methods to allow fission gas emission from fuel tubes. The method shown in 2 a uses closure of the upper opening of the fuel tube 203 a with a sintered metal plug 201 a where the sinter pore size is adjusted to allow gasses to pass but not to allow liquids, either the fuel salt 202 a or the coolant outside the fuel tube to pass. FIG. 2 b shows a fuel tube 203 b containing fuel salt 202 b where the fuel tube is capped by a diving bell assembly 205 b. The diving bell assembly 205 b allows gas to pass from the fuel tube 203 b to the coolant 207 b via vents 206 b in the wall of the fuel tube, but coolant 207 b sucked into the diving bell assembly 205 b cannot mix with the fuel salt 202 b. FIG. 2 c shows a fuel tube 203 c vented directly to the gas space above the coolant 207 c via a narrow tube or capillary tube 208 c. | Use in a nuclear fission reactor of a sacrificial metal in a molten salt fuel containing actinide halides in order to maintain a predefined ratio of actinide trihalide to actinide tetrahalide without reducing actinide trihalide to actinide metal. A method of maintaining oxidation state of a molten salt containing actinide halides. The method comprises contacting the molten salt continuously with a sacrificial metal, the sacrificial metal being selected in order to maintain a predefined ratio of actinide trihalide to actinide tetrahalide without reducing actinide trihalide to actinide metal. A fuel tube containing a sacrificial metal is also described. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to post tensioning concrete anchor assemblies and, more particularly, to an anchor plate assembly for post tensioning structures.
2. History of the Prior Art
The technology for the post tensioning concrete structures is well established. Anchor plate assemblies are generally utilized for the securement of post tensioning filaments or tendons that extend through a body of concrete. The tendons, which are generally steel cables, impart compressive loads to, and enhance the strength of, the concrete in a manner that is sometimes not economically and/or mechanically possible with conventional rebar construction. Anchor assemblies on opposite end of the tendons are critical to this technique, and the effectiveness of the interconnection between the anchor plates and the tendons, as well as the sealing of the assembly, is critical to the effective life span of the construction.
Corrosion is an important consideration in the utilization of post tensioning assemblies. It is well known that corrosion can cause deterioration in the anchor plate assemblies and this can result in a deleterious effect on the ultimate strength of the concrete. It is for this reason that the steel fibers that generally comprise the post tensioning cables are usually placed within a plastic sheath which extends through the slab. This sheath must, however, be cut off short of its connection to the anchor assemblies in order to allow the anchor wedges thereof to directly engage the steel fibers. The exposed fibers must, however, be subsequently covered in some respect in order to prevent the problems of subsequent corrosion.
In order to facilitate sealing of post tensioning cables and the ultimate elimination of moisture therearound, grease is often used in or around the caps and tubular members that are generally used to cover the plate extending around the anchor plate. A thorough description of such prior art approaches, as well as related innovations in anchor plate assemblies and improvements therein, is set forth and shown in U.S. Pat. No. 4,821,474 which issued to Alan Rodriguez on Apr. 18, 1989. In this patent, an anchor plate assembly of a type utilized in post tensioning configurations is set forth and described in detail. Likewise other prior art patents also referenced in this particular patent include U.S. Pat. No. 4,363,462 to Wlodkowsi, et al., issuing on Dec. 14, 1982 and U.S. Pat. No. 4,121,325 to Bruinette, et al., issuing in 1978.
The above mentioned prior art references teach a variety of approaches to post tensioning anchor assemblies for prestressed concrete. As stated in certain ones of those references, the elimination of corrosion of the post tensioning cables and in the anchor plate assemblies is a primary consideration in order to prevent failure in the tensioning cable. The assembly of sealing caps and "stackable" tubular members on opposite sides of the anchor plate itself is well known in this particular technology. It would be an advantage however to provide an improved method of securing the cap and the tendon covering tubular members to the anchor plate for purposes of both shipping and handling of the anchor plate assembly as well as its subsequent use.
The present invention provides such an advance over the prior art by providing a post tensioning anchor plate assembly that utilizes aligned, cylindrical portions, or bosses, each being formed with a recess constructed in the outer cylindrical surfaces thereof. The recess or groove, is used to matingly engage protruding lips formed inside the plastic cap and inside the tubular connection member specifically adapted for connection to opposite sides of the anchor plate. In this manner, both the cap and the tubular connection member (or adapter) can be reliably secured to, and effectively sealed with, the anchor plate enhancing the reliability thereof. A compression ring is also provided for securement around the cap and tubular connection member to enhance the sealing thereof.
SUMMARY OF THE INVENTION
The present invention pertains to a post tensioning anchor plate assembly and its method of use. More particularly, one aspect of the invention includes an improved anchor plate assembly of the type wherein a generally rectangular plate having oppositely disposed, cylindrical mounting members, or bosses, is adapted for placement in a concrete formation for post tensioning thereof with a tendon, or cable, running therethrough. The improvement comprises the oppositely disposed bosses being concentrically aligned one with the other and each having at least one recess formed in the outer surface thereof adapted for a mating engagement of a generally cylindrical coupling element thereover for sealed engagement therewith. One of the coupling elements comprises a cap adapted for sealing an outer portion of the mounting plate. Another of the coupling elements includes a tubular mounting member adapted for sealed engagement with the boss extending into the concrete formation for receipt of the cable therein. The tubular mounting member includes an inwardly extending lip adapted for mating engagement with the recess of the boss.
In another aspect, the above described invention includes the cylindrical bosses each being formed with a circumferential groove substantially therearound adapted for receiving a generally circumferential lip projecting inwardly from the coupling elements. The oppositely disposed mounting members may also be connected by a single aperture formed therethrough in a tapered configuration therewith.
In yet another aspect, the invention includes a method of mounting a protective cap to a post tensioning mounting plate comprising the steps of forming said mounting plate with oppositely disposed bosses of generally cylindrical construction, forming a groove in the outer surface of the bosses, forming an inwardly projecting lip in the cap, and positioning the cap over the boss in mating engagement therewith.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for further objects and advantages thereof, reference may now be had to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is an exploded, perspective view of one embodiment of an anchor plate assembly constructed in accordance with the principles of the present invention;
FIG. 2 is an exploded, perspective view of the anchor plate assembly of FIG. 1 taken from the opposite side thereof; and
FIG. 3 is a side elevational, cross sectional view of the anchor plate assembly of FIG. 1 taken along lines 3--3 thereof and illustrating the assembled configuration including a cable and a tubular member covering the cable within a concrete structure.
DETAILED DESCRIPTION
Referring first to FIG. 1, there is shown an exploded perspective view of one embodiment of an anchor plate assembly 10 constructed in accordance with the principles of the present invention. In this view, there is presented the side of the assembly 10 which faces outwardly of a concrete structure. The outwardly facing assembly 10 includes a generally rectangular anchor plate 12 having a mounting boss 14 upstanding therefrom. The boss 14 includes a generally cylindrical outer surface 16 and a generally planar, end face 18. A central bore 20 having an outer end 21 is formed therethrough. The bore 20 is preferably tapered for receipt of anchoring wedges which will be described in more detail below.
Still referring to FIG. 1, a cap 22 having a generally planar outer end 24 is constructed for mounting to, and sealing with, the cylindrical surface 16 of boss 14. The cap 22, as shown herein, has a portion 26 cut away for purposes of illustrating a lip 28 formed therein. The lip 28 is adapted to engage a groove 30 formed in the surface 16 of the boss 14 of the anchor plate 12 upon installation thereover. A groove 31 is also formed around the outer portion of cap 22 in the region of lip 28 to therein provide means for receiving a ring, or the like, therein for exerting an inwardly directed pressure upon the lip 28 as it engages groove 30 to enhance the sealing thereof. This aspect will be described in more detail below.
Referring now to FIG. 2, there is shown an exploded, perspective view of the inwardly facing portion of the anchor plate assembly of FIG. 1. This view is taken from the side of plate 12 facing inwardly toward a concrete structure. The anchor plate 12 is shown to be constructed with oppositely disposed, concentrically aligned bosses 14 and 40. Boss 40 extends from a substantially planar side 42 of anchor plate 12. From the boss 40, opening 44 of aperture 20 can be seen, which opening 44 is of smaller diameter than the end 21 shown in FIG. 1. The boss 40 has an outer surface 50 of generally cylindrical, but smaller diameter construction compared to the surface 16 of boss 14. The boss 40 is adapted to engage a tubular member (shown in FIG. 3) or tubular member adapter 60 adapted for assembly thereto in sealed engagement therewith. In that regard, a groove 52 is formed in the surface 50 which groove 52 is adapted to engage a lip 54 formed within the adapter 60. The adapter 60 and the cap 22 (shown in FIG. 1 ) may be made of plastic such as polyethylene, or the like, which material provides sufficient flexibility and resilience for expanding over the respective boss mounting surfaces. This expansion allows the lips 28 and 54 to contract over and engage the respective grooves therein for sealed engagement therewith.
Still referring to FIG. 2, the adapter 60 is constructed with a first cylindrical body portion 62 in which inwardly directed lip 54 is formed. Outwardly of lip 54 a groove 64 is located to therein provide means for receiving a ring or other securement member therearound to apply pressure to the lip 54 while it is in engagement with groove 52 of boss 40. Extending rearwardly from cylindrical portion 62 is extension section 66 concentrically formed therewith and having a smaller diameter relative thereto. A transition, or shoulder region 68 is shown to connect first portion 62 with second section 66. The section 66 is formed with a central aperture 70 that is sized to permit receipt of a cable therein and extension therethrough into the aperture 20 of anchor plate 12. A center line 72 is representatively shown to illustrate both the exploded view of the tubular member adapter 60 and the center thereof wherein a cable would lie therethrough. Such a cable is shown in FIG. 3.
Referring still to FIG. 2, a coil ring 80 is representatively shown to illustrate the placement thereof in the groove 64 of the body portion 62 of tubular member adapter 60. Ring 80 is but one embodiment of the type of structure which could be utilized to apply compressive pressure to the lip 54 during its engagement with groove 52. A similar ring structure would be provided in groove 31 of cap 22, as shown in FIG. 1.
Referring now to FIG. 3, there is shown a side elevational, cross sectional view of an assembled anchor plate assembly 10 of the type shown in FIG. 1. A tendon 90 is shown extending therefrom within a concrete structure 92. The tendon, or cable 90, shown in FIG. 3 is also constructed with a protective sheath 94 which has been cut away in the region 96 to expose the steel fibers 98 thereof in the vicinity of the anchor plate 12. The fibers 98 are exposed to allow placement of securement wedges 100 within the tapered bore 20 of anchor plate 12. The wedges 100 secure cable 90 relative to both the anchor plate and the concrete structure 92. The wedges 100 are each tapered, as is the bore 20 of the anchor plate 12, for securing said cable against movement after post tensioning. In this embodiment, the raw strands 98 of cable 90 are shown to be in direct engagement with the anchoring wedges 100, as is conventional in such construction.
Still referring to FIG. 3, the anchor plate 12 is secured in the concrete structure 92 as a result of a pour of concrete therearound. A cavity 101 is shown formed around the end 18 of anchor pl ate 12. This step is conventional in the prior art. The cavity 101 is typically formed by a "pocket former" (not shown), which cavity permits access to the anchor plate 12 to permit the tensioning of the cable 90 and the placement of the wedges 100 there against. Referring still to FIG. 3, the cavity 101 comprises a first tapered region 103 formed adjacent an inner cylindrical region 105. The cylindrical region 105 exposes the portion of the boss 14 having the groove 30 formed therein. In this manner, a cap 22 may be received thereover, and the lip 28 of cap 22 matingly engages the groove 30 of boss 14 as herein shown. A compression ring 110, as described above, is shown placed within the outer groove 31 of cap 22 to therein apply inward pressure from lip 28 against the groove 30 of boss 14. This configuration facilitates the sealing of the assembly to inhibit moisture infiltration. A cavity 111 is formed within the cap 22. The cavity 111 may be filled with grease in accordance with prior art techniques. The grease has been used to reduce the area which moisture can accumulate and to further facilitate the sealing thereof to prevent moisture infiltration therethrough.
Still referring to FIG. 3, the tubular adapter 60 is likewise shown secured to the inside of anchor plate 12 which is rigidly secured within the concrete structure 92. A compression ring 120 is shown disposed within the groove 64 of tubular adapter member 60. This assembly permits the generation of inward pressure through lip 54 against the groove 52 of boss 40 as described above. A conventional tubular extension member 130 is shown mating with the tubular adapter member 60 in the region of cylindrical section 66. The tubular member 130 is disposed in a press fitting engagement with the section 66 of tubular adapter member 60 to provide a sealed engagement there-between. It may likewise be seen that the distal end 131 of tubular member 130 is shown to tightly engage the sheath 94 of cable 90 to also provide a sealed engagement therewith. In this manner, a sealed cavity 133 is formed around cable 90, which cavity can be filled with grease or the like in accordance with conventional post tensioning technology. It may be seen that the cavity 133 extends within the tubular adapter member 60 and through the boss 40 thereof to terminate, in this particular view, against the wedges 100 disposed therein. It should be noted that the wedges 100 are typically tapered metal members, and spaces may exist therebetween, in which instance, cavity 133 would merge into cavity 111, which may also be filled with grease.
The actual utilization of grease and/or other compounds in the sealing of the cap and tubular members of the present invention is conventional in this technology. Likewise, utilization of tubular member 130 is conventional in the art, as is the use of a sheathed cable 90. The present invention thus pertains specifically to means for improving the assembly of a cap outwardly of an anchor plate as well as the use of a tubular adapter member 60 inwardly of the anchor plate 12 for sealed engagement around cable 90. As stated above, any variety of rings 80 (as shown in FIG. 2) and 110 and 120 (as shown in FIG. 3), is possible. The rings 80, 110, and 120 may be snap rings, steel spring sections, elastic members such as O-rings, and related structures. The present invention provides a method of and apparatus for improving the sealed configuration between such elements as cap 22 and tubular extension member 60 and the respective mounting bosses.
It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the method and apparatus shown or described has been characterized as being preferred it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined in the following claims. | A post tensioning anchor plate assembly comprising an anchor plate and coupling elements therefor. The anchor plate is constructed with a pair of oppositely disposed, concentrically aligned cylindrical bosses, or mounting members, projecting from opposite sides of a generally rectangular plate. The oppositely disposed bosses define, on the inside surface thereof, a common tapered bore adapted for receiving a post tensioning cable therethrough and securement thereof for post tensioning of a concrete section. The outside surface of each boss is likewise constructed with a circumferential groove adapted for receiving an inwardly projecting lip of an appropriate plastic cap or tubular adapter secured thereover. In this manner, the plastic cap and tubular adapter can be mounted to opposite sides of the anchor plate in sealed engagement therewith for facilitating improved reliability of the post tensioning anchor plate assembly. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to cleaners and polishes, and, more particularly, to a combination all purpose cleaner and polish for rubber, leather, vinyl polymer, acrylic, wood and plastic surfaces.
Polish compositions for rubber, vinyl, leather, acrylic, wood, plastic and the like in the prior art generally consist of a polish formulation which in some circumstances can also be combined with a preservative and renewing agent. In applying these polishes of the prior art, the user typically needed first to select a suitable cleaner composition with which to pre-clean the surfaces to be polished, as well as an application tool for the cleaner, such as a cloth or sprayer. The cleaning step generally entailed use of a cloth or the like which could be the applicator, if any. Once the cleaner was used and the surface sufficiently cleaned, it was then necessary to allow the surface to dry. This was generally accomplished by air drying or by utilizing a dry cloth or towel to remove any moisture remaining on the surface. In order to apply the polish, one needed to utilize an additional application tool, such as a cloth or sprayer, for the application process. In some situations, additional tools, such as a buffing cloth, or the like, were needed to further enhance the appearance of the surface. It is not uncommon for the prior art cleaning and polishing process to utilize up to four different tools for the application, drying and buffing steps.
There is, therefore, a need in the industry to provide a combination cleaner and polish which can be applied to a surface in a single step using a single applicator tool, eliminating the heretofore required multiple steps carried out by applying multiple products to the surface being cleaned and polished using multiple application, drying and polishing tools.
SUMMARY OF THE INVENTION
It is, therefore, an object of this invention, to provide a single formulation for both cleaning and polishing surfaces, wherein the formulation is incorporated onto an abrasive towel substrate, eliminating the need for using multiple formulations and multiple tools, and saving both time and costs associated with such multiple steps and tools.
It is a further object of this invention to provide a single formulation for cleaning and polishing surfaces using a single applicator tool, wherein the formulation and applicator tool are able to cleanse embedded soils, and the residue of the soils is absorbed within the substrate in a single step through a combination of both the cleaner portion of the formulation and the abrasive action of the towel substrate so that additional tools such as sprayers, cloths or the like are not required.
It is also an object of this invention to provide a single formulation for both cleaning and polishing surfaces using a single applicator tool, wherein the formulation, when dried, will not leave an undesirable film on the surface, so that there will be no need subsequent to drying for removal or polishing as with a buffing cloth or a similar device, in order to achieve a desired appearance on the treated surface.
It is another object of this invention to provide a single formulation for both cleaning and polishing surfaces using a single applicator tool, wherein the cleaning and polishing article of this invention further comprises a plurality of saturated towels provided in a continuous rolled cylinder inside a sealed container having a recloseable opening for easily and continuously supplying the towels.
In accordance with these and other objects which will become readily apparent from the description of the invention contained herein, the combination cleaning and polish formulation and abrasive applicator tool of this invention combines in a one step method what, in the prior art, required as many as four steps. Specifically, this invention accomplishes the steps of cleaning, preserving, renewing, and polishing a surface in a single step using a single application/drying/polishing tool.
The surfaces which can be cleaned and polished by the tool of this invention include, but are not limited to, rubber, leather, vinyl polymer, acrylic, wood and plastic surfaces. This tool is particularly useful in the automotive industry in connection with the cleaning and polishing of tires, rubber sealing strips, vinyl tops, dash boards, seats and the like. Due to the nature of the automobile, these surfaces are typically subjected to extreme environmental stresses, including extreme weather conditions, dirt, grease, and the like. As is readily apparent, the tool of this invention is equally useful in connection with the cleaning and polishing of many surfaces in a variety of applications and industries other than those associated with automobiles.
Accordingly, the present invention comprises a combination all-purpose cleaner and polish impregnated in an abrasive substrate, the substrate presenting an abrasive surface and being capable of absorbing and retaining a fluid, and a nonabrasive aqueous cleaner-polish formulation absorbed in the substrate, the cleaner-polish formulation comprising a cleaning emulsion which includes surfactant and a solvent, and a polishing agent, whereby the cleansing action and the polishing action are both achieved by the cleaner-polish formulation and the abrasive surface of the substrate. In addition, the cleansing action is further achieved by the absorption of the dissolved or softened soil residue into the substrate. The article further comprises a plurality of towels provided in a continuous roll housed in a sealed container, and a lid associated with the container and having a recloseable opening for supplying the towels. A key component of the formulation is a cleaning emulsion comprising a surfactant, water, and an organic solvent. A preferred embodiment of the cleaner-polish formulation comprises about 15-40% by weight of the cleaning emulsion, about 20-70% by weight of a polishing agent, and about 10-50% by weight water. In another preferred embodiment, the formulation further comprises about 1-20% by weight of an additional solvent, and 1-10% by weight of a preservative.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A cleaner and polish article is provided and is comprised of an abrasive substrate having a cleaner-polish formulation incorporated thereon. The abrasive substrate of the preferred embodiment comprises a cloth-like towel having at least one abrasive surface. The abrasive surface can be formed in several different manners from a number of different materials. According to one embodiment of this invention, the towel can be similar to that described in U.S. Pat. No. 4,833,003 to Kimberly-Clark entitled “Uniformly Moist Abrasive Wipes,” issued May 23, 1989, which is herein incorporated by reference in its entirety. The towel encompassed within the scope of this invention has two opposed surfaces. An abrasive component is permanently attached to or an integral part of at least one surface of the towel, although it is possible for the abrasive component to be present on both surfaces. The abrasive component may comprise a layer of fibers and/or globules bonded to the surface of a substrate, such as a layer of fibers or fiber bundles and small, minute generally spherical masses having a wide range of acceptable diameters, namely from about 40 microns to about 200 microns. Due to the irregular nature of such fibers and globules, it is recognized that the diameter is approximate, as such fibers and globules typically are not perfectly round. These fibers/globules can be formed from polymeric materials by known means, such as by meltblowing a polymer melt. It is not necessary to incorporate a combination of fibers and globules, as it is possible to utilize either component by itself as the abrasive. Alternatively, the abrasive component may comprise any of a number of known particulates which can function as an abrasive when bonded onto a substrate.
The term “abrasive” as used herein refers to a surface texture that enables the towel to produce a mild scouring or abrading action to effectively remove dirt or other contaminates which are embedded in a surface to be cleaned and polished, such as leather or vinyl, while not harming such surface by scratching or the like. The degree of abrasiveness can vary widely, depending primarily upon the abrasive component on the substrate and the degree of texture which is formed by such abrasive component. Typically, the abrasive surface is somewhat coarse and roughened as compared to a smooth surface of the towel. In accordance with a preferred embodiment of this invention, the abrasive is adequately mildly abrasive so as to avoid scratching the surface intended to be cleaned by the towel, while having sufficient abrading qualities to effectively remove embedded dirt and contaminants from the object being cleaned. Although the abrasive properties are very mild, in the sense of not cutting or scouring the object being cleaned, the texture is relatively high so as to accomplish removal of dirt and other contaminants from the object being cleaned.
To be optimally effective, the abrasive component of this invention accounts for a minimum of 10% and a maximum of 90% of the surface area of the abrasive side of the towel, with the opposite side having a smooth surface for wiping and buffing. It is anticipated that both sides of the towel can have abrasive ingredients incorporated thereon and that the percentage of abrasive component on each side can differ as desired.
In addition, the towel must be capable of absorbing and retaining a predetermined amount of fluid, such as the aqueous cleaning and polish formulation contemplated by the preferred embodiment, sufficient to provide a uniformly moist towel. The absorbent character of the towel can be achieved by a system of voids or pores which absorb and tightly retain the cleaner-polish formulation, such as by capillary action. The towel should also be capable of readily releasing the liquid during use. The specific void or pore volume of the towel structure regulates the amount of fluid which can be retained in the towel. The cleaner-polish formulation is incorporated onto the towel and is capable of removing a variety of soils from the surface to be treated. This formulation has a viscosity sufficient to be easily absorbed into the pores or voids of the towel through capillary action.
The composition of a preferred embodiment of the cleaner-polish formulation of this invention comprises, generally, an aqueous cleaning emulsion including a surfactant, water, and an organic solvent, a polishing agent, and a carrier. In another preferred embodiment, additional solvents are incorporated. Optionally, preservatives, biocidal agents and odorants may also be incorporated.
The organic solvent contemplated for use in the formulation of the invention is preferably capable of solubilizing greasy, oily soils, and can include aliphatic solvents, dibasic esters, petroleum oils, vegetable oils, alcohols, glycols, glycol ethers, furfuryls, petroleum distillates and polyols. The aliphatic solvents, such as odorless mineral spirit, are particularly preferred, as they are highly effective in removing petroleum based contaminants and are relatively safe from a toxicity standpoint. The organic solvent should not be harmful to human skin at the concentrations indicated, and cannot be harmful to vinyl, plastic, rubber or leather surfaces. The surfactants employed are preferably nonionic, anionic or amphoteric, and function to promote water/oil single phase emulsions of the ingredients. The polishing agent employed in this invention is preferably a silicone emulsion, although other suitable polishing agents may be employed. The carrier comprises a nonflammable vehicle which also acts as a solvent for water-soluble soils. The inert ingredients contemplated for use with the formulation may include fragrances or odorants, preservatives, and microbial agents.
According to one embodiment, a key cleaning ingredient of the formulation is an aqueous cleaning emulsion. The emulsion is broadly comprised of 2-40% by weight of an organic solvent, 2-20% by weight of a surfactant, and 60-95% by weight water. Optionally, 0-8% by weight of inert ingredients can be included in the composition. In another embodiment, the aqueous cleaning emulsion is comprised of 1-20% by weight d-Limonene, 1-20% by weight of a nonionic surfactant, 1-20% by weight mineral spirits, and 60-95% by weight water. In a preferred embodiment, the aqueous cleaning emulsion is comprised of the following composition, with both the preferred and the acceptable ranges of ingredients being indicated:
Preferred
Acceptable
Ingredients
% By Weight
Range of %
Odorless Mineral Spirits
4.70
1.00-20.00
d-Limonene (terpene)
9.50
1.00-20.00
BHT
0.05
0.01-1.00
Bactericide
0.05
0.01-0.50
Nonionic surfactant
3.00
1.00-10.00
Perfume
0.05
0.01-0.50
Sorbitol
1.00
0.50-5.00
Sodium Lauryl Sulfate
4.00
1.00-10.00
Potassium Sorbate
0.20
0.10-0.50
Preservative
0.30
0.10-0.50
Water
77.15
60.00-95.00
This aqueous cleaning emulsion includes both ionic and nonionic ingredients to emulsify and suspend a variety of soils, as well as bactericides and antifungus/mold agents. One example of a nonionic surfactant useful in this invention is Tergitol 15-S-5, manufactured by Union Carbide Corporation.
The following examples of aqueous cleaning emulsions are presented to illustrate this invention, but are not intended to limit this invention in any way.
EXAMPLE 1
General Purpose Formula
Ingredients
% By Weight
Odorless Mineral Spirits
4.70
d-Limonene (terpene)
9.50
BHT
0.05
Bactericide
0.05
Nonionic surfactant
3.00
Perfume
0.05
Sorbitol
1.00
Sodium Lauryl Sulfate
4.00
Potassium Sorbate
0.20
Preservative
0.30
Water
77.15
EXAMPLE 2
Heavy Duty Cleaning Formula
Ingredients
% By Weight
Odorless Mineral Spirits
7.00
d-Limonene (terpene)
7.00
BHT
0.01
Bactericide
0.01
Nonionic surfactant
10.00
Perfume
0.01
Sorbitol
5.00
Sodium Lauryl Sulfate
10.00
Potassium Sorbate
0.10
Preservative
0.10
Water
60.77
EXAMPLE 3
Long-Lasting Quick Touch-Up Formula
Ingredients
% By Weight
Aliphatic Solvent
8.00
Terpene
1.00
BHT
1.00
Bactericide
0.50
Nonionic surfactant
1.00
Perfume
0.50
Sorbitol
0.50
Sodium Lauryl Sulfate
1.00
Potassium Sorbate
0.30
Preservative
0.50
Water
85.70
EXAMPLE 4
Quick Drying Formula
Ingredients
% By Weight
Aliphatic Solvent
1.00
Terpene
20.00
BHT
0.20
Bactericide
0.20
Nonionic surfactant
2.00
Perfume
0.10
Sorbitol
2.00
Sodium Lauryl Sulfate
2.00
Potassium Sorbate
0.30
Preservative
0.20
Water
72.00
An example of a preferred cleaner-polish formulation for use in the invention, and which incorporates the above cleaning emulsion, is as follows, with both the preferred and the acceptable ranges of ingredients being indicated:
PREFERRED
ACCEPTABLE
INGREDIENT
% BY WEIGHT
RANGE OF %
1.
Aqueous cleaning emulsion
20.00
15.00-40.00
(set forth above)
2.
Solvent
2.00
1.00-10.00
3.
Preservative
3.00
1.00-10.00
4.
Polishing Agent
40.00
20.00-70.00
5.
Odorant
0.20
0.10-1.00
6.
Biocidal agent
0.02
0.005-0.10
7.
Water
34.78
10.00-50.00
The aqueous cleaning emulsion, whose composition is described above, contains water, a surfactant and an organic solvent, and is useful in removing dirt and contaminants from the surface to be cleaned so as to enable the polishing agent to effectively polish the surface. The preferred solvents for use in the formulation include glycol ethers and dibasic esters. Particularly preferred is Glycol Ether PM (propylene glycol monomethyl ether) which is an excellent solvent for inks, resins, and paint polymers.
The polishing agent employed in the cleaner-polish formulation of the present invention can be any of a number of known polishes, and is preferably a silicone emulsion such as an emulsion of an organopolysiloxane fluid or fluid mixture in water. Typically, the water works to expand the particular surface being cleaned and polished, such as rubber or polymer, thus assisting in the penetration of the polysiloxane fluid into the treated surface. Such an emulsion is particularly effective when a dimethylpolysiloxane fluid is selected, particularly when the surface to be treated is rubber or vinyl. It is also effective to add to the dimethylpolysiloxane fluid about 10% by weight of an amino-substituted dimethylpolysiloxane fluid to increase the adherence to the surface for longer post application protection. This amino-substituted formulation is especially advantageous when treating metal surfaces. Other modifications, such as the use of phenyl and other substituted dimethylpolysiloxane fluids, may be desirable if the modifications are tailored to the particular material being treated and/or the stresses of the environment to which the material is exposed. Silicone is an effective polish because it is able to penetrate the surface of the treated substance, thus protecting it.
The silicone emulsion useful in accordance with this invention typically comprises water in the amount of from about 65% to about 660% by weight, based on the weight of the silicone fluid. It is possible, however, for the amount of the water to be as high as about 5000% by weight.
Preservatives may also be incorporated into the formulation and can include, but are not limited to, propylene glycol, ethylene glycol, and/or any polyol. In the preferred embodiment of this invention, propylene glycol is used as the preservative. In addition to functioning as a preservative, propylene glycol can also act as a solvent, and can provide temperature stability to the formulation.
The odorant is an optional but desirable component of this formulation. Useful in this invention are a number of suitable known odorants or perfumes. The preferred odorant in the formulation of the present invention is determined, in part, by the particular application desired. For example, when used as a leather cleaner and polish, it may be desirable to add a leather odorant to the formulation.
It is also generally preferred to incorporate a biocidal agent, which acts to prevent bacteria growth in the formulation. Any of a number of biocides can used in accordance with the formulation of this invention. One example of a suitable biocidal agent is Myacide BT.
The carrier comprises a nonflammable material which also acts as a solvent for water-soluble soils. It also acts to interrelate the other substances of the formulation and facilitate their application. In a preferred embodiment, water is the carrier/solvent used in this formulation.
The following examples of cleaner-polish formulations which are distributed throughout an abrasive towel substrate are presented to illustrate this invention, but are not intended to limit this invention in any way.
EXAMPLE 1
General Purpose Formula
Ingredient
% By Weight
Aqueous cleaning emulsion
20.00
(general purpose formula)
Glycol Ether PM
2.00
Propylene Glycol
3.00
Silicone emulsion
40.00
Odorant
0.20
Myacide BT
0.02
Water
34.78
EXAMPLE 2
Extra Shine Formula With Strong Scent
Ingredient
% By Weight
Aqueous cleaning emulsion
15.00
(quick drying formula)
Glycol Ether PM
2.00
Ethylene Glycol
3.00
Silicone emulsion
60.00
Odorant
1.00
Biocidal agent
0.02
Water
18.98
EXAMPLE 3
Heavy Duty Cleaning Formula
Ingredient
% By Weight
Aqueous cleaning emulsion
40.000
(heavy duty cleaning formula)
Glycol Ether PM
2.000
Polyol
3.000
Polishing Agent
20.000
Odorant
0.200
Biocidal Agent
0.005
Water
34.795
EXAMPLE 4
Long-Lasting Quick Touch-up Formula
Ingredient
% By Weight
Aqueous, cleaning emulsion
15.00
(long-lasting quick touch-up formula)
Glycol Ether PM
7.40
Propylene Glycol
7.40
Silicone emulsion
20.00
Odorant
0.10
Biocidal agent
0.10
Water
50.00
EXAMPLE 5
Quick Drying Formula
Ingredient
% By Weight
Aqueous cleaning emulsion
15.00
(quick drying formula)
Glycol Ether PM
10.00
Propylene Glycol
10.00
Silicone emulsion
50.00
Odorant
0.20
Biocidal Agent
0.02
Water
14.78
In preparing the cleaner-polish article of a preferred embodiment, a plurality of abrasive towels is provided, preferably in a continuous, perforated, roll. The line of perforation presents a line of weakness by which said towels can be easily separated. Said towels are inserted on-end into a selectively resealable, preferably cylindrical container, with the axis of the cylinder being aligned in an essentially vertical orientation. Of course, it is anticipated that an alternative preferred embodiment of this invention could provide a stack of individual towels instead of the continuous roll of towels. The cleaner-polish formulation is then added to the container, preferably by pouring it over the roll of towels, thereby saturating the towels with the formulation within the container. The capillary action associated with the void volume of the towel, as discussed above, causes the formulation to be distributed evenly throughout the.roll of towels.
An example of a suitable container for holding the towels comprises an essentially airtight lid on the top portion thereof which can be selectively sealed, said lid comprising a hinged cap having an opening positioned thereunder. This opening allows for the passage of towels from the interior of the sealed container via the opening, whereby individual towels can be removed by pulling the towel and tearing the same off of the roll at the perforated line located between each individual towel. The opening is appropriately sized to provide means for removing excess liquid from each individual towel as it is removed from the container.
In use, an individual towel is removed from the container as described above. When properly prepared, the towel contains an amount of the cleaner-polish formulation sufficient to thoroughly accomplish the tasks previously mentioned. As the towel is rubbed onto the surface to be treated, it releases the cleaner-polish formulation for continuous cleansing of soils without the need to apply additional cleaners. The abrasive character of the towel facilitates removal of embedded soils found on the treated surface. In one embodiment, the towel is composed of a non-woven polypropylene that absorbs the softened soils to achieve a clean surface for receiving the polish portion of the formulation.
The cleaner and polish article of the present invention is useful in cleaning, polishing and protecting leather, vinyl, rubber, plastic, acrylic, wood and numerous other surfaces. Some specific applications of this invention include, but are not limited to, automotive uses such as tires, vinyl tops, dash boards, door panels, hoses, belts, vinyl and leather seats, as well as a variety of other diverse applications including luggage, shoes, bumpers, vinyl siding, sports equipment and appliances.
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference!to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. | A cleaner and polish article comprises a substrate capable of absorbing and retaining a fluid and having two opposed surfaces wherein at least one surface is abrasive, and a nonabrasive aqueous cleaner and polish formulation absorbed, in the substrate. The cleaner and polish formulation comprises an aqueous cleaning emulsion containing water, a surfactant and an organic solvent, a polishing agent, and a carrier, whereby cleansing and polishing action is achieved by the formulation, and abrasive cleansing action and polishing action is achieved by the cleaner and polish formulation as well as by the abrasive surface of the substrate. The substrate is further capable of absorbing the dissolved or softened soil residue to assist in the cleansing action. The substrate can comprise a cloth-like towel. A plurality of such towels is provided in a continuous roll placed in a selectively sealable, essentially airtight container. An opening in the lid of the container allows the user to remove individual towels which contain the appropriate amount of cleanser thereon. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an entrance device according to the preamble of claim 1.
2. Description of the Prior Art
Such an entrance device is known from European patent application 0 296 134. This document discloses the application of a revolving door having at its output and input sections sliding doors designed to move in cooperation with the movement of the revolving door. The movement or position of the revolving door and the respective sliding doors can also be switched to independent operation whereby the revolving door is put in a stationary position in parallel with the passage through the revolving door assembly. The sliding doors may or may not move to and fro in their path in order to either provide a full and restricted passage or to provide a pure sliding door operation. In normal use, the entrance device of EP 0 296 134 requires a rather complicated cooperation of said sliding doors and the revolving door assembly.
SUMMARY OF THE INVENTION
It is the object of the invention to provide an entrance device according to the preamble of claim 1, having simpler operation and allowing for automatic switch over from one type of operation to the other depending on environmental conditions. In this way, high energy saving and optimal draft exclusion can be obtained in a first way of operation, whereas large capacity can be provided in a second type of operation.
The objectives of the invention can be obtained with the entrance device according to the preamble of claim 1, which is characterized in that the entrance device comprises two revolving doors and that the sliding door is arranged in the pathway between said two revolving doors.
In a certain aspect of the invention, the entrance device has a programmable control system including sensors for measuring environmental parameters, such as temperature, air humidity, wind speed or the like, to determine, on the basis thereof, the most convenient way of using the entrance means.
It is acknowledged that EP 0 296 134 discloses the use of a detector or similar sensing means to initiate a starting pulse for the drive motors that are used to operate the revolving door assembly and the sliding doors as disclosed in said publication. Such detector is, however, merely used to detect a person that is approaching the entrance device. It does not provide any means to identify the most convenient way of using the entrance means based on environmental conditions, such as temperature, air humidity and other weather conditions.
In a favourable embodiment of the entrance device according to the invention it also comprises an air treatment device and/or an air curtain. Such apparatus are known in the art but support the objective of the invention to provide energy saving and yet a high capacity entrance device depending on circumstances at hand.
According to the invention the entrance device can be adapted to environmental circumstances providing optimal comfort, a low energy use and a desired capacity, throughout the year. Preferably, the control system automatically switches to the most convenient manner of operation of the entrance device based on the measurements of the said environmental conditions. As an alternative the control system may be switched to semi-automatic operation whereby advice is given on the basis of the parameters measured by the sensors with regard to the most convenient operation under the measured circumstances.
BRIEF DESCRIPTION OF THE DRAWING
The invention will hereinafter be illustrated with reference to the drawings, which give a highly schematic representation of an exemplary embodiment of the invention.
FIG. 1 is a highly schematic plan view of the embodiment of the entrance device according to the invention.
FIG. 2 shows a block diagram of the control system of the entrance device of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an entrance device placed in an outer wall or facade of a building. In this exemplary embodiment, the entrance device comprises a revolving door lock 2, an automatic sliding door 3 and an air treatment device 4. The revolving door lock consists, in this case, of two revolving doors 5 and 6 which can each revolve about a vertical axis 9 and 10, respectively, within two casing walls 7 and 8, respectively, having the shape of a segment of a circle. Between both revolving doors 5, 6 of the revolving door lock 2, an intermediate part or corridor 13 is positioned, offering space to a sliding door 3 and an air treatment device 4 in its ceiling. The revolving doors 5, 6 each consist of two aligned door wings, which are provided on both sides of the axis 9, 10 concerned and which either constitute an integral unit or consist of separate parts. The revolving doors 5, 6 are driven by a synchronized driving device, which, in this case, consists of two electric motors 11, 12, which are synchronized electronically. In the normal operating mode, both revolving doors 5, 6 revolve synchronously, in such a way that the revolving doors 5, 6 are angularly offset 900 with respect to each other. As a result of this, the passage is always closed by at least one revolving door, so that the draught-preventing effect is guaranteed at all times. In the position represented in FIG. 1, the revolving door lock 2 is inoperative, the revolving doors 5, 6 being secured in alignment, parallel to the passage. Further details of this revolving door lock can be found in the earlier Dutch Patent No. 9201723, the content of which is incorporated herein by reference.
As mentioned before, an intermediate part is positioned between the revolving doors 5, 6, which houses an automatic sliding door including detection means (not represented) and a driving means 14. This sliding door may, as desired, close the entrance device, be secured in an opened position or function as an automatic sliding door. The sliding door may, instead of straight panels, also comprise sliding panels, which have the shape of a segment of a circle and which are adapted to the curvature of the casing walls 7, 8, and can therefore move on the outer side thereof.
The air treatment device 4, which, for example, consists of an air heater for heating the air coming from outside through the sliding door 3. The air treatment device 4 could be replaced by or supplemented with an air curtain, as is known in the art.
According to the invention, the operation of the entrance device is controlled by a control system, as has been represented schematically in FIG. 1 and 2, which makes sure that the entrance device operates in the most optimal way for the environmental circumstances concerned, in particular the weather conditions. Thus, the entrance device will function as a revolving door in cold or windy weather. In a calmer type of weather, the revolving doors 5, 6 can be secured in the rest or summer position, and the sliding door 3 can be switched on, while in cold weather the air treatment device 4 can be switched on as well. When the weather is very fine, the entrance device can be opened completely.
In order to achieve this automatic operation, the control system comprises one or more indoor sensors 15 and a plurality of outdoor sensors 16. These sensors may, for example, consist of temperature gauges, hygrometers, wind gauges, pressure gauges (for measuring any pressure difference between the inside and the outside of the building) and possibly other sensors. These sensors 15, 16 are connected to a processing unit 17 including a display 18 for presenting data, such as the parameters measured. The processing unit is connected with a system control 19 having actuating elements 20 for influencing the system control from outside. The system control controls the revolving door lock 2, the sliding door 3 and the air treatment device 4. This control can be fully automatic, which means that the desired entrance mode is selected on the basis of the parameters measured and the data stored in the memory of the processing unit. Alternatively, the control system can be semi-automatic, giving an advice on the basis of the parameters measured as to what is the most optimal operating mode of the entrance device, which advice may, or may not, be followed by an operator and an adjustment may be made by way of the actuating elements 20. It is, of course, also possible to switch over completely to manual operation, and take no account of the parameters measured. A manager of a supermarket may, for example, still decide to use the sliding door in windy weather, when it is very busy and a large capacity is desired. The comfort and the energy saving effect may thus be sacrificed to some extent to that end.
It will be clear from the foregoing that the invention provides an entrance device which excels in versatility and user comfort.
The invention is not limited to the exemplary embodiment represented in the drawings and described in the foregoing, which can be varied in various ways within the scope of the invention. It is, for example, possible to replace the revolving door lock represented in the drawings by a single two, three or four-wing revolving door, in which former case the sliding door can be incorporated in the wings of the two-wing revolving door. The sliding door may be equipped with a one or two-sided escape facility to provide an emergency exit by flapping away the panels when pressure is exerted on the middle of the sliding door. | An entrance device for placement in a facade of a building includes at least two revolving doors. Each of the revolving doors has an input section and an output section. A sliding door provides closure of the input and output sections of the two revolving doors. The sliding door is disposed between the two revolving doors. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application is related to copending application Ser. No. 117,187 filed concurrently herewith and assigned to the same assignee as this invention. This invention relates to a cooled flameholder assembly.
BACKGROUND OF THE INVENTION
This invention relates to gas turbine, or jet, engines, and, in particular, to engines which include afterburners downstream of a core engine with means for adding fuel to exhaust flow for augmenting thrust.
A bypass jet engine includes a low pressure compressor (LPC) for pressurizing inlet air to the engine; a core engine for producing thrust and also for driving the LPC; and, further, may include an afterburner in which fuel is added to the core engine exhaust, which is then ignited to provide thrust augmentation. The bypass engine is so called because it includes an annular outer casing which is substantially concentrically mounted about the core engine casing to form an annular bypass duct therebetween. The discharge air from the LPC is divided between the bypass duct and the core engine.
In general, engine lines mature and as uprated versions of existing engines are derived, one of the design methods to obtain increased engine output has been to increase turbine inlet temperature with a consequent increase in the inlet temperature to the afterburner. The flashback margin of the fuel/air mixture scrubbing the afterburner hardware is thereby proportionately reduced. Flashback is the movement of the flame front upstream of its design position against the direction of the main gas flow and toward the flameholder and the fuel injection source. Flashback margin is the difference in actual temperature of the exhaust gases and the temperature thereof which would cause flashback.
If the turbine exhaust temperatures increase sufficiently, then the afterburner flame front would move upstream in the afterburner combustion chamber toward the flameholder. The flameholder would then increase in temperature due to the radiation/convective heat loads, which could result in reduced flameholder design life.
Accordingly, it is an object of the present invention to provide an improved flameholder.
Another object of the invention is to provide means for cooling the flameholder.
Another object of the invention is to provide means for increasing flashback margin in an afterburner.
SUMMARY OF THE INVENTION
The invention comprises an improved flameholder assembly having means for cooling an aft facing surface thereof. Disclosed are structures for channeling core engine discharge gases or bypass duct air for cooling the aft surface.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, in accordance with a preferred exemplary embodiment, together with further objects and advantages thereof is more particularly described in the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic sectional view of a bypass jet engine including an afterburner having a flameholder assembly in accordance with one embodiment of the present invention.
FIG. 2 is an upstream facing end view of the flameholder assembly taken along line 2--2 of FIG. 1.
FIG. 3 is an enlarged schematic view of a portion of a flameholder assembly in accordance with one embodiment of the present invention.
FIG. 4 is a plan view of several partitions taken at line 4--4 of FIG. 3.
FIG. 5 shows a section of the flameholder assembly of FIG. 1 and a cutaway showing of a partition therein.
FIG. 6 shows a section of a flameholder assembly and a cutaway showing of a partition therein in accordance with an alternate embodiment of the invention.
FIG. 7 is a schematic of a portion of a flameholder assembly similar to FIG. 3 showing another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an exemplary, gas turbine engine 11 of the type which may be considered a bypass jet engine. The engine 11 includes a low pressure compressor (LPC) 13, which is located at the air inlet end of the engine 11. The LPC 13 is followed, with respect to the direction of the airflow, by a core engine 15, which includes a high pressure compressor, a combustor and high pressure and low pressure turbines (not shown). The core engine 15 is surrounded by an annular inner casing 17. An annular bypass duct 19 is defined in part by the casing 17 and an annular outer casing 21, which is substantially concentric and spaced from the inner casing 17. The dashed flow arrows 22 indicate that portion of the LPC 13 discharge air which is sent through the core engine 15, and the solid line arrows 24 indicate the other portion of the LPC 13 discharge air which is channeled through the bypass duct 19.
Downstream from the core engine 15, in the direction of airflow, is an afterburner 25. A flameholder assembly 31, in accordance with one embodiment of the present invention, is positioned in an inlet of the afterburner 25. Fuel is introduced into the afterburner 25 through a plurality (only one shown) of fuel delivery pipes 35. The fuel is mixed with a portion 26 of the bypass duct airflow 24 and then ignited by at least one igniter 39 to provide thrust augmentation in the engine 11. The air portion 26 from the bypass duct 19 is added to the core engine 15 exhaust gas flow through an annular mixer device 41, which is well known in the aircraft engine technology. The afterburner 25 further includes an inner combustor liner 45 and a variable area exhaust nozzle 49. The foregoing general description is given to acquaint the reader with a general description of the environment in which the present invention operates and should not be taken as limiting with respect to the description of the invention itself.
FIG. 2 illustrates an upstream facing end view of the flameholder assembly 31. The flameholder assembly 31 includes a radially outer flameholder 51 and a radially inner flameholder 55. The outer flameholder 51 is in the form of a plurality of bluff bodies, and the inner flameholder 55 is in the form of an annular V-shaped gutter ring. The inner flameholder 55 is supported from the outer flameholder 51 by a plurality of circumferentially-spaced support links 57. Although it is not specifically shown in any of the drawings, the outer flameholder 51, which, in turn, supports the inner flameholder 55, is itself supported from the outer casing 21 by support links in a manner familiar to aircraft engine builders. The outer flameholder 51 communicates with the inner flameholder 55 by at least one, with two being used in the embodiment illustrated, crossfire gutter 61, which causes a flame initially appearing on the downstream surface of the outer flameholder 51 to propagate radially inwardly toward the inner flameholder 55.
FIG. 3 shows a schematic sectional view of the outer flameholder 51 and adjacent structures without the attached inner flameholder 55 or crossfire gutters 61. Further, in an effort to simplify the drawing, a single schematic fuel spraybar 65 extending from the fuel pipe 35 is shown as entering and discharging fuel into the outer flameholder 51. Referring back to FIG. 1, the fuel delivery pipe 35 is actually connected to a plurality of radially inwardly extending spraybars which include both main fuel spraybars and pilot fuel spraybars. The main fuel spraybars inject fuel in the axially downstream direction, from points radially inwardly and outwardly of the outer flameholder 51 and, in one example, may include as many as twenty-four pipes, whereas there may be half as many pilot fuel spraybars. Other numbered parts of the outer flameholder 51 and adjacent structures are as previously described.
Further, the outer flameholder 51 includes a radially outer annular member 71 and a radially inner annular member 73 defining an inlet 70 therebetween at an upstream end and an outlet 72 at a downstream end. These two members may be joined together at the inlet end 70 of the outer flameholder 51 by a plurality of rounded fasteners or pegs 101, as is shown in FIG. 7. In addition, extending between the inner and outer members 71, 73 is a plurality of hollow, airfoil-shaped partitions 79. The solid arrowheads 74 indicate a first portion of core engine, or turbine combustion discharge gas which flows around the partitions 79, as will be described in conjunction with the description of FIG. 4.
The inner member 73 of the outer flameholder 51 has an upstream facing scoop 83 fastened to it. In the preferred embodiment, there is a plurality of such scoops 83 fastened to the radially inner surface of the inner member 73 with holes 85 formed through the inner member 73 which communicate with at least some of the interiors of the partitions 79. The flow arrows 76, having open heads, indicate the flow of a second portion of the turbine discharge gas into the interiors of the partitions 79. In a preferred embodiment, there may be one scoop 83 for directing gas into a corresponding one partition 79 through a corresponding one hole 85 formed through the inner member 73.
It is important to note at this point that the gas which is directed through each partition 79 is fuel- and oxygen-depleted turbine discharge gas, i.e. most, if not all, of the fuel and oxygen therein has completed combustion. As will be described below with respect to an alternate embodiment, the gas may be alternatively bypass air but, in either case, no fuel is added to the gas in the partitions 79. Fuel is added, through the spraybars 65, to the gas which flows around the partitions 79. The fuel-depleted gas is indicated in FIGS. 3 and 4 by means of the open arrowheads 76, and the gas to which fuel is added is indicated by means of the solid arrowheads 74.
With reference to FIG. 4, which is a plan view taken along line 4--4 of FIG. 3, there is shown a plurality of circumferentially-spaced partitions 79 and spraybars 65, with one spraybar 65 associated with each pair of adjacent partitions 79 in this exemplary embodiment. The partitions 79 each include a leading edge portion 80 and a trailing edge portion 82. The partitions 79 are shaped and sized in accordance with the requirements of fuel and gas mixing within the outer flameholder 51 so that the fuel/air mixture is correct and further that the flame occurs on the downstream side, or aft surface, 84 of the trailing edge portion 82 of the outer flameholder 51 rather than at the point where the igniter 39 is located. The partitions 79 also impart a swirl or turning effect on the fuel and turbine discharge gas, collectively referred to as the fuel/air mixture, to enhance mixing thereof. Also shown in FIG. 4 are the holes 85, formed through the inner member 73 under the leading edge portion 80 of the partition 79, which admit gas into the interior of the partitions 79.
FIGS. 3, 4 and 5 should be studied together with reference to the present invention. Like numerals are used to identify like members which were previously explained. Also, the reader is reminded that the open arrowheads 76 identify fuel-depleted gas, whereas the solid arrowheads 86 indicate carbureted gas, i.e. gas 74 which is mixed with fuel.
FIG. 5 shows a partial section of the flameholder assembly 31 with the leading edge portion 80 of partition 79 additionally shown as rotated toward the viewer ninety degrees in order to show flow lines as well as further details of construction with respect to the partition 79. The view of the flameholder assembly 31 is of the aft, or downstream, face 84 thereof. FIG. 5 shows a preferred embodiment of the outer flameholder 51 in which the aft face 84 of the partition 79 is formed with film-cooling discharge louvers 95. The louvers 95 discharge fuel-depleted gas, as indicated by the open arrowheads 76. The film cooling of the aft face 84 of the partitions 79 lowers metal temperatures at the aft face 84. It is further important to realize that while fuel-depleted film-cooling gas 76 is being discharged from louvers 95, carbureted or fuel-enriched gas 86 is being discharged from between the partitions 79 so that, in accordance with the flow arrow diagram, it is clear that the film-cooling gas 76 will be immediately adjacent to the aft face 84 of each partition 79, whereas the fuel-rich gas 86 will be discharged in a stream or layer which is beyond the film-cooling gas 76 relative to the aft face 84 of the partition 79. Thus, the film-cooling gas 76 is interposed between the partition 79 or partition aft surface 84 and the fuel/air mixture 86 channeled between the partitions 79. It should also be realized that the carbureted mixture 86 has been ignited by the igniter 39 and, thus, creates a flame front downstream of the aft face 84 having a higher temperature than the relatively cool gas 76 discharged through the louvers 95.
Moreover, specifically at the onset of any flashback, when the carbureted gas 86 is starting to burn and is thus very hot relative to design metal temperatures, film-cooling gas 76 scrubbing the aft face 84 is now thousands of degrees cooler than gas 86, thus providing an effective cooling film during actual sustained or sporadic flashback conditions.
In addition to providing film cooling of the aft face 84, the gases 76 also provide a barrier film which keeps the flame front from contacting the aft face 84. Using previously burned gases 76 is also advantageous because they are no longer combustible themselves, which provides a more effective film-cooling barrier, for example.
Referring to FIG. 6, which shows an alternate embodiment of the invention in which the aft face 84 of the partition 79 is cooled by convection, within the partition 79 a wall 97 is disposed approximately parallel to the aft surface 84 of the partition 79 defining a flowpath 98 adjacent to the aft surface 84. In this embodiment, the flow of uncarbureted or fuel-depleted gas 76 is across the interior surface of the aft face 84 of the partition 79, and the gas 76 is discharged from a trailing edge 96 of the partition 79 through a discharge opening 99. While both embodiments are effective to provide cooling of the aft face 84 of the partition 79, it is pointed out that where the cooling gas 76 to the interior of the partition 79 is turbine discharge gas 76, such gas 76 is not only fuel-depleted but it is also oxygen-depleted. In accordance with one of the objectives of this invention, the sweeping of the aft surface 84 of the partition 79 with oxygen- and fuel-depleted gas 76 will further diminish the chance occurrence of flame on the aft face 84 of the outer flameholder 51.
Finally, FIG. 7 shows another embodiment of the invention in schematic form. FIG. 7 is intended to be similar to FIG. 3, except that the spraybar 65 has been removed for the sake of clarity. The previously-mentioned rounded fastener or peg 101 is shown for joining the upstream ends of the outer and inner flameholder members 71, 73.
In this embodiment, a portion of bypass air 24 is taken from the bypass duct 19 and channeled to the interior of the partition 79 through a tube 105 and opening 107 in the outer member 71. The opening 107 is functionally equivalent to the opening 85 in the preferred embodiment. There is a plurality of scoops 111 which are fastened to the inner liner 17, which forms the inner boundary of the bypass duct 19. The advantage of this embodiment is that the bypass air 24 is much cooler than the turbine discharge gas 74.
While there have been described herein what are considered to be preferred embodiments of the invention, other modifications may occur to those of ordinary skill in the art. It is intended to cover in the appended claims all such modifications which fall within the true spirit and scope of the claims. | The uprating of existing jet engines increases the operating temperatures within the engines and also increases the tendency for flashback in some afterburner type engines. Afterburner type engines include a pilot fuel delivery pipe which is included between inner and outer annular members of a flameholder. Downstream from the pilot, partitions direct an ignited fuel/air mixture into the afterburner chamber. The afterburner flame is downstream from the flameholder, but under conditions of increased temperature the afterburner flame will tend to migrate upstream toward the flameholder. To avoid this tendency, the flameholder includes means for discharging gas which cools the flameholder metal itself while also decreasing the downstream air temperature, thereby decreasing the potential for flashback. In one embodiment, fuel and oxygen depleted turbine discharge gas are used to further decrease the tendency toward flashback. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This Application is a Section 371 National Stage Application of International Application No. PCT/ GB2009/001649, filed 1 Jul. 2009 and published as WO 2010/001120 on Jan. 7, 2010, in English, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
The present invention relates to ironing boards and ironing tables, and more specifically to improvements to the robustness, and ease and speed of use.
BACKGROUND ART
FIG. 1 shows a conventional ironing board 1 comprising an ironing surface 10 supported by a pair of legs 20 , 22 . The legs 20 , 22 extend from the underside of the ironing surface to a pivot 30 and further to feet 40 . At the pivot 30 the legs meet in a crossed scissor-like configuration. There are four feet 40 formed at the ends of the pair of legs 20 , 22 . Adjacent to one end of the ironing surface 10 is an iron rest 50 on which the iron can be placed, and that is not damaged by the heat of the iron.
Commonly, one of the legs is rotatably coupled to the underside of the ironing surface, and the other leg is slidably coupled to the underside of the ironing board. This arrangement allows the ironing board to be collapsed by the user for storage. The collapse of the ironing board is achieved by the movement of the legs which allows the ironing board 1 to be stored in a narrow flat space. To provide a robust surface for ironing, the legs 20 , 22 must be held firmly in position when the ironing board is in the upright position for use shown in FIG. 1 .
FIG. 2 shows two arrangements used on conventional ironing boards to allow the legs to collapse down flat. FIG. 2 a shows the underside of a conventional ironing board 1 and how the pair of legs are coupled to the underside. Leg 22 is arranged to rotate about a fixed pivot attached to the underside of the bar. The other leg 20 has a cross beam 65 at the top end of the leg. The cross beam is arranged between a pair of slide surfaces 70 . By sliding the cross beam 65 in the direction of the arrow 75 , the height of the ironing surface can be adjusted. By sliding the cross beam further in the direction of the arrow 75 , the legs will close flat against the underside of the ironing surface. In FIG. 2 a , the position of the cross beam 65 can be fixed by the lever arm 80 . The lever arm is pivoted at its center. Towards the one end of the lever arm 80 are a series of hooks 82 (two shown in FIG. 2 a ) which the cross beam fits into. The hooks 82 prevent the cross beam 65 and legs 20 , 22 from sliding and the ironing board collapsing. The hook restraining the cross beam can be released by moving the handle at the other end of the lever arm towards the ironing surface. Conveniently, the handle is biased away from the ironing surface, and the required releasing motion is a squeezing of the handle toward the ironing surface. This causes the lever arm to pivot and the cross beam is released from the hook to allow the ironing board to be collapsed flat.
The prior art device of FIG. 2 a has a problem in that the legs are only constrained when the hooks 82 engage with the cross beam 65 , that is, when the ironing board is in an ironing position with the legs open. Multiple hooks can be used to provide the ironing surface at different heights to allow the user to select the most comfortable. However, the legs are not restrained in the closed position. Thus, a user when picking up the ironing board with the legs in the closed position, from for example, a cupboard, has to grasp the legs to prevent them flying open and hitting the user or surroundings as the ironing board is moved.
FIG. 2 b shows a common alternative to the above prior art mechanism. In this case, the lever arm with hooks is replaced by a long rod 90 extending from cross beam 65 . Intersecting with the long rod 90 is bar 94 . The bar 94 is arranged to pivot about axis A through the center of the bar. At one end of the bar 94 is a tab 96 with a circular hole 98 through it, as shown in FIG. 2 c . The other end of the bar 94 has a handle for turning the rod 94 about axis A. The handle may be biased away from the ironing surface such that the hole 98 in the tab 96 grips the rod 90 . When the handle is squeezed toward the ironing surface the tab is rotated bringing the tab 96 perpendicular to the rod 90 effectively increasing the cross-section of the hole as viewed along the rod 90 . With the tab perpendicular to the rod, the hole no longer grips the rod 90 and the rod can slide freely through the hole 98 . This movement of the rod allows the legs to be moved between a closed or collapsed position, and an upright or open ironing position.
The prior art device of FIGS. 2 b and 2 c partly overcomes the problem of holding the legs in the closed position when the ironing board is carried. However, the legs are not held very securely in the closed position because the braking mechanism is only designed to act in one direction to hold the legs in the open ironing position. Furthermore, the device also suffers from a different problem. The mechanism holding the ironing board legs in the open position consists of a hole in a tab of metal gripping against a rod. This does not provide a robust and solid position to the ironing surface, and can sometimes slip thereby lowering the height of the board.
The stability and robustness of the position of the ironing surface is of particular importance when the ironing board is used with a steam generator iron rather than a conventional iron. Such steam generator irons include a large and cumbersome base unit that is filled with 1 to 2 liters of water. Thus, the stability and robustness of the ironing board is particularly important when used with a steam generator.
Another problem with conventional ironing boards such as that of FIG. 1 , is that the tip 55 is designed to be useful for ironing a variety of different garments, but this results in the surface not being particularly suited to any go/went. For example, the narrowing of the width of the ironing surface is designed to be useful in ironing trousers because the top of the trouser can be placed over the tip to allow the waist and seat of the trousers to be ironed. However, the tip is also shaped to allow the shoulder yoke of a shirt to be ironed. Because the tip of the ironing board is narrowed, the area of the shoulder yoke that can be ironed at one time without movement of the shirt is small. Hence, ironing shirts requires the shirt to be repositioned many times during ironing. A number of attempts have been made to improve the shape of ironing boards, such as in U.S. Pat. Nos. 5,016,367, 6,151,817, WO 2007/018791, and U.S. Pat. No. 6,286,237, but each of these attempts is limited by ease of use and the shapes of ironing surface that can be provided.
A further problem associated with conventional ironing boards is that the ironing surface cools rapidly. The surface is normally metal covered with fabric, or a fabric coated with foil. The foil is used to reflect the heat, However, with conventional ironing boards thick layers must be ironed on both sides to remove creases, and multiple layers cannot be ironed at once to remove all creases successfully.
Another problem with conventional ironing boards is that after use for several years the fabric top that forms the ironing surface 10 begins to migrate. A user will tend to iron garments using ironing strokes of the same direction. As a result, after several years of ironing, the fabric top will begin to slide towards one side. It is difficult to reposition the top because the fabric adopts the shape given by the edge of the ironing board. Repositioning results in the ironing surface not being flat. Some ironing boards allow the fabric top to be replaced, but this is usually a difficult task and the same problems will only recur again a few years later.
SUMMARY OF THE INVENTION
The present invention provides an ironing board system, comprising: an ironing board having a flat elongate surface for ironing, the surface having a perimeter which at an end comprises three adjacent same shaped arcs or curved portions; and at least one attachment or wing having a first edge complementary to each of said arcs, the system adapted such that the wing detachably couples to the ironing board at any of the three arcs to extend the surface for ironing in different ways. The coupling of the wing results in the ironing surface being extended to form one of a plurality of shapes. By ironing board we also mean ironing tables and the like. The system has advantages in that the shape of the end of the ironing board can be changed to suit the garment being ironed. For example, by coupling one wing to the central arc, the ironing surface is extended to provide a tapered tip suitable for ironing the seat of trousers. By coupling two wings to the outer arcs, the tip of the ironing board is matched to the shoulder yoke of a shirt. In addition because the arcs are the same, a single wing can be fitted interchangeably at any of the arcs.
The wing or attachment may have a shape such that when coupled to the ironing board at any one of the three arcs, a second edge of the wing meets another of the arcs in a continuous curve or line. That is, a second edge of the wing aligns into an arc of the ironing board such that the edge lines up with end trajectory of the arc to continue that trajectory. Thus, the direction of the end of the arc aligns with the direction of the second edge of the wing.
The wing or attachment may have a shape such that when coupled to the ironing board at any one of the three arcs, a second edge of the wing meets another of the arcs at a tangent.
The flat surface of the ironing board is tapered by the outer two of the three arcs, and when the wing is coupled to the ironing surface at the central one of the three arcs the taper may be extended. The taper may also considered to be a wedge shape. This tapered of wedge shape is suited to ironing inside narrow items such as the seat of trousers.
When the wings are fitted to the outer two of the three arcs, the center arc and edges of the wings may form a shoulder yoke shape. The arcs of the perimeter are preferably convex. The first edge of the wing is non-concave.
The wing may be considered to be of generally triangular shape having three sides or edges, one of them being curved complementary to the arcs of the ironing board.
The perimeter of the ironing surface may comprise two sides separated by two ends, wherein of the three equally shaped arcs the outer two arcs meet the sides, and the central one of the three arcs meets the outer arcs at corners.
There is also provided an ironing board or ironing table comprising: an elongate flat ironing surface having a perimeter or circumference comprised of two sides separated by two ends, wherein at one end (the end furthest from an iron rest if provided) the perimeter or circumference is formed of three curved or linear portions, the first curved or linear portion meeting the first side, the third curved or linear portion meeting the second side, and the second curved or linear portion meeting the first and third curved or linear portions at corners. The shape of the ironing surface is optimised for ironing shirts. If curved portions are included, the curvature is matched to the curvature across the shoulder yoke of shirts.
The three curved or linear portions may have substantially the same shape. The radius of curvature of a curved portion may increase towards the extremities of the curved portion. The edge having curved portions is convex.
The ironing board may further comprise receiver means for receiving an attachment for extending the ironing surface. Receiver means may be provided at each of the three portions to receive an attachment at the three portions. By providing three positions at which an attachment may locate, the shape of the tip of the ironing board can be changed to suit the garment being ironed. Furthermore, since all receiver means are the same, a single attachment may be used at all three locations.
The present invention also provides an ironing board/table attachment for extending the ironing surface of an ironing board, the attachment having an ironing surface, the circumference of the ironing surface comprised of first and second straight edges and a third edge, the three edges meet at corners to define a substantially triangular ironing surface, wherein the attachment comprises mounting means arranged to releasably couple the attachment to an ironing board. The third edge may be curved or linear to fit the curved or linear portions of the ironing board described above. If the second portion of the tip is curved, the curvature combined with the extended ironing area provided by the attachments or wings is advantageously matched to the shape of the shoulder yoke of shirts, thereby making ironing of shirts easier because they do not require as much repositioning.
The mounting means may be a retractable tongue.
An ironing board system comprising an ironing board or ironing table described above, and the attachment described above. The attachment may comprise a retractable tongue, and the ironing board may comprise a slot for receiving the tongue, the slot positioned so as to align the ironing surface of the attachment coplanar with the ironing surface of the ironing board. The retractable tongue is used to provide support to the attachment when fitted to the ironing board.
The present invention also provides an ironing board system, comprising: an ironing board having an elongate flat ironing surface; an attachment arranged to detachably couple to the ironing board to extend the ironing surface, wherein the ironing board comprises a plurality of receivers for receiving the attachment at a plurality of positions. The ironing board may have three receivers for receiving the attachment at three positions. The attachment may be coupled to any one of the receivers to provide different shaped ironing surfaces. A plurality of attachments may be provided may also be provided.
When an attachment is coupled to the ironing board at a first position, the extended ironing surface tapers toward a point, but the actual point may be rounded. This tapered shape finds advantage in making it easier to iron the seat of trousers.
The ironing board system may further comprise a second attachment, wherein when the two attachments are coupled to the ironing board at second and third positions, the extended ironing surface widens to form a hammerhead shape. This shape may also be considered to consist of a pair of wings. The shape provides the advantage of fitting the shoulder yoke of shirt to allow the shirt to be ironed without having to reposition the shirt many times.
The perimeter of the ironing surface may have one or more curved portions, and when coupled to the ironing board the one or two attachments meet one or more curved portions tangentially or collinearly.
The present invention further provides an ironing board, comprising: an ironing surface; and an iron rest having a connector coupled to the ironing surface and an iron support arranged to receive an iron, wherein the iron support is arranged for rotation with respect to the connector and about an axis through said iron support. The iron support may also be known as a turntable. The iron support may be a platform, ring or rim that can be rotated. The advantage of the turntable of the present invention is that it allows the iron to be put at rest from a variety of directions, while also being more compact that prior art devices.
The iron rest may be provided adjacent to an edge of the ironing surface.
The present invention also provides an ironing board having an ironing surface, and comprising: a frame or base arranged to support an ironing surface; legs coupled to the frame and arranged to support the frame at a height suitable for ironing; wherein the ironing surface is a layer or sheet covering at least one side of a rigid panel, the rigid panel detachably coupled to the frame. Because the rigid panel is removable, the layer or sheet forming the ironing surface can be changed easily. The rigid panel is preferably flat.
When the rigid panel is mounted to the frame, the layer or sheet is gripped between the rigid panel and the frame preventing movement of the layer or sheet. This arrangement results in the sheet or layer of the ironing surface being clamped between two surfaces preventing movement.
The sheet or layer may be fabric, fabric covered foil, or foil.
The panel may be detachably coupled to the frame by an engageable member. The engageable member may be a foot protruding from the panel and has a ridge for engagement with a notch in the frame.
The present invention also provides an ironing board, comprising: an ironing surface supported by a frame or case; legs to support the frame and arranged to move between a closed position for storing the ironing board and an open position for use of the ironing board, at least one of the legs being slidable with respect to the ironing surface; and a brake assembly arranged to releasably restrain, with respect to the ironing surface, the position of the slidable leg, the brake assembly comprising: a slide rod or connecting rod coupled to the slidable leg, the slide rod extending from the leg to a bearing surface; a cam mounted on a shaft, the shaft having a handle arranged to rotate the cam about the shaft, wherein the shaft is biased towards a first position in which the cam bears against the slide rod pushing the slide rod against the bearing surface thereby restraining the position of the leg.
The handle may be squeezed toward the ironing surface by the user to move it to a second position. In the second position the cam has rotated and no longer causes the connecting rod to bear against the guide thereby allowing the connecting rod to slide. Thus, when the handle is pressed the connecting rod and legs can move.
The connecting rod may be enclosed, fully or partially, within a guide, and the bearing surface may be part of the guide.
The present invention additionally provides an ironing board comprising an ironing surface and legs to support the ironing surface, at least one of the legs being arranged to slide with respect to the ironing surface between a storage position and an open position, the ironing board further comprising a pair of brakes to restrain the position of the at least leg. The pair of brakes may be operated independently, such that the ironing board cannot be collapsed or folded away without operating both brakes. This provides a safety advantage because it prevents a child from operating the brakes inadvertently closing the board. independently operable.
The first brake assembly may have a cam and slide rod arranged to prevent movement of the slide rod in a first direction, and the second brake assembly may have a cam and connecting rod arranged to prevent movement of the connecting rod in a second direction opposite to the first direction. A pair of brakes arranged to operate in opposite directions prevents the legs falling open or closed.
Additionally, the first brake may also provide a smaller braking force in a second direction, and the second brake may provide a smaller braking force in the first direction.
The ironing board may comprise an ironing surface and legs for supporting the ironing surface, at least one of the legs being movable with respect to the ironing surface between a storage position and an open position, wherein the ironing board further comprises a pair of brakes, the first brake arranged to releasably restrain at least one of the legs in the storage position, and a second brake arranged to releasably restrain at least one of the legs in the open position. Because the pair of brakes are required to be operated together to close or open the ironing board, this provides a safety feature preventing a child from closing the legs while the ironing board is in use, perhaps with a hot iron.
There is also provided an ironing board comprising a surface for ironing supported by a rigid panel, the ironing surface formed of a flexible sheet, wherein between the flexible sheet and the rigid panel is a resilient non-permeable interlayer to cushion the ironing surface and prevent steam penetration from the ironing surface to the rigid panel. The steam does not penetrate through to the rigid panel, but is reflected by the interlayer through the flexible sheet. The rigid panel may comprise holes, such as a mesh, or be a solid panel. The flexible sheet may be fabric.
The interlayer may be closed cell foam. The closed cell foam may have a thermal conductivity of less than 0.2 W/m·K. The foam may have a hardness of 5 to 40 on the OO Durometer scale. The foam may be extruded silicon sponge, such as is used for seals and gaskets.
Alternatively, the interlayer may be a resilient material laminated with plastic. The resilient material may be open cell foam, felt, or other matted or non-woven material.
The ironing boards described above may have an ironing surface comprising a flexible sheet covering a rigid panel, disposed between the sheet and rigid panel may be a heat retaining material. The heat retaining material may have a thermal conductivity less than 5 W/m/K, less than 0.5 W/m·K, or less than 0.2 W/m·K. The heat retaining material may be a silicon foam or silicone foam. Such heat retaining material does not cool quickly and thereby provides an increased decreasing duration. The foam is preferably resilient. The foam is also preferably closed cell foam to prevent water or steam penetrating through the foam such that the steam is reflected back from the foam. Alternatively, the foam may be of any kind but is laminated with a membrane through which the steam cannot pass. Preferably the membrane is on the side of the foam closest to the ironing surface such that water is not absorbed in the foam.
Preferably, the foam has a hardness of 5 to 40 on the OO Durometer scale, or even between 5 and 20 on the same scale.
The sheet of the ironing surface may be a felt or felt-like material. The rear side of the felt may be laminated with a polymer or plastic material to retain heat. A foam material may also be used as the heat retaining material and does not necessarily need to be limited to the felt or fabric.
The ironing board attachment described above may also include a heat retaining material as described above.
There is also provided an ironing board comprising: an elongate flat ironing surface having a perimeter comprised of two sides separated by two ends, wherein at one end the perimeter is formed of three portions, the first portion meeting the first side, the third portion meeting the second side, and the second portion meeting the first and third portions at corners.
The three portion may be curved portions. The three curved portions may have substantially the same shapes. The radius of curvature of each curved portion may increase towards the extremities of the curved portion.
A first side may be tangential to the first curved portion, and the second side may be tangential to the third curved portion.
The angle between a first end of one of the curved portions and a second end of one of the curved portions may be 140° to 150°.
The normal to the center of the first portion may preferably be at angle of 140° to 155° to the normal to the center of the third portion, or more preferably 145° to 150°.
The shape of the ironing surface is preferably symmetric about an axis centrally along the length of the surface.
The two sides of the ironing surface are preferably parallel.
Optionally, the ironing board further comprises receiver means for receiving an attachment for extending the ironing surface, a receiver means provided at each of the three portions to receive an attachment at the three portions.
There is also provided an ironing board attachment or wing for extending the ironing surface of an ironing board, the attachment having an ironing surface, the perimeter of the ironing surface comprised of first and second straight edges and a third edge, the three edges meeting to define a substantially triangular ironing surface, wherein the attachment comprises mounting means arranged to releasably couple the attachment to an ironing board.
Preferably, the third edge is a curved edge. The mounting means may be arranged to align the ironing surface of the attachment coplanar with the ironing surface of an ironing board. The mounting means may be a retractable tongue. The first and second straight edges may be at an angle of 60° to 75° to each other, or more preferably at an angle of 65° to 70° to each other.
There is also provided an ironing board system comprising the ironing board described above and the attachment or wing described. The attachment or wing maybe adapted to releasably couple to the ironing board at a plurality of positions. The attachment is adapted to couple to the ironing board at a first position, the edge formed by the second portion of the ironing board meets the first or second straight edge of the attachment tangentially or collinearly. In addition, the attachment is adapted to couple to the ironing board at a second position, the edge formed by the first portion of the ironing board meets the first or second straight edge of the attachment tangentially or collinearly.
The attachment may comprise a retractable tongue, and the ironing board comprises a slot for receiving the tongue, the slot positioned so as to align the ironing surface of the attachment coplanar with the ironing surface of the ironing board.
There is also provided an ironing board system, comprising: an ironing board having an elongate flat ironing surface; and an attachment arranged to detachably couple to the ironing board to extend the ironing surface, wherein the ironing board further comprises a plurality of receivers for receiving the attachment at a plurality of positions.
The ironing board may have three receivers for receiving the attachment at three positions. The attachment may couple to the ironing board at a first position such that the extended ironing surface is tapered. The ironing board system may further comprise a second attachment, wherein when the two attachments are coupled to the ironing board at second and third positions, the extended ironing surface widens to form a hammerhead shape.
The perimeter of the ironing surface may have one or more curved portions, and when coupled to the ironing board the one or two attachments meet one or more curved portions tangentially.
The present invention also provides an ironing surface comprising a sheet covering a rigid panel, wherein between the sheet and rigid panel is a heat retaining material having a thermal conductivity less than 5 W/m/K.
The heat retaining material may be a foam material. The foam material may be silicon foam. The heat retaining material may be a polymer laminated on the sheet. The sheet may be fabric. The sheet may be felt or a felt-like material.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention, along with aspects of the prior art, will now be described with reference to the accompanying drawings, of which:
FIG. 1 illustrates an ironing board of the prior art;
FIG. 2 a shows the mechanism for locking the legs of an ironing board in open and retracted positions according to a first prior art example;
FIGS. 2 b and 2 c are detailed views of the mechanism for locking the legs of an ironing board in open and retracted position according to a second prior art example;
FIG. 3 is an isometric perspective view of an ironing board according to an embodiment of the present invention;
FIG. 4 is a detailed plan view of the tip of the ironing board according to an embodiment of the present invention;
FIG. 5 is a detailed plan view of the tip of the ironing board according to an embodiment, showing the location of a shirt during ironing;
FIG. 6 is a detailed plan view of a wing for attachment to the ironing board;
FIG. 7 a shows the tip of an ironing board with a pair of wings fitted;
FIG. 7 b shows the placement of an adult's shirt on an ironing board with wings fitted;
FIG. 7 c shows the placement of an child's shirt on an ironing board with wings fitted;
FIGS. 8 a , 8 b , 8 c show the tip of the ironing board in three configurations, respectively no wing fitted, one wing fitted, and two wings fitted;
FIG. 9 is an isometric perspective view of the underside of the ironing board and wing according to an embodiment of the present invention;
FIG. 10 a shows in isometric perspective the turntable iron rest of an embodiment of the present invention;
FIGS. 10 b , 10 c show the turntable iron rest in two different orientations;
FIG. 10 d shows the turntable iron rest in cross-section with an iron resting thereon;
FIG. 11 shows a removable panel that forms the rigid part of an ironing surface;
FIG. 12 shows in detail the coupling mechanism for locking the removable panel to the case or frame of the ironing board;
FIG. 13 shows in cross-section the removable panel clamping the ironing surface sheet to the frame;
FIG. 14 , shows the ironing board from the underside, with legs open;
FIG. 15 shows the braking mechanism for restraining the legs in a fixed position;
FIGS. 16 a - 16 c show a guide and slide rod of the braking mechanism; and
FIGS. 17 a - 17 b show the different versions of the braking mechanism used on the two sides of the ironing board.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments provide an ironing board or ironing table having an improved tip shape which is also optimised for attachment of removable wings, turntable iron rest, improved materials for the surface of the ironing board, an improved braking mechanism to hold the legs of the ironing board in position, and a removable top to allow the cover to be changed easily and also to hold the cover in position more rigidly. Each of these improvements is described below. Each of these improvements may be included by itself in an ironing board or with any number of the other improvements.
FIG. 3 shows an ironing board 100 having an ironing surface 110 and three linear legs 120 , 122 a , 122 b . These may be circular or square tubes, solid, or preferably of rectangular cross-section. Two of the legs 122 a , 122 b are fixed parallel to each other. The third leg 120 passes between the two legs 122 a , 122 b . At the end of each of the legs are feet 140 , 142 . The feet extend laterally from the legs to provide widely spaced points were the feet touch the floor. Spacing the feet more widely than the legs increases the stability of the ironing board. The feet may extend perpendicularly to the legs or may be curved as shown in FIG. 3 . At the ends of the feet where contact is made with the floor, pads may be provided. Legs 122 a , 122 b are parallel and the positions where the legs meet foot 142 are slightly spaced apart.
The legs 120 , 122 a , 122 b meet at a pivot 130 comprised of a circular shaft passing perpendicularly through the legs. Spacing the legs apart on the pivot rod 130 are spacers 132 . The pivot rod 130 is held in position by nuts or other fastening means on the end of the rod. The legs can pivot with respect to each other about the pivot, though legs 122 a , 122 b are fixed together at the foot and cannot move with respect to each other.
At the top of the legs is provided ironing surface 110 . The ironing surface may be supported on a frame. The legs may be connected to the underside of the frame by the prior art means described above, or by further means described below. One of the legs will be pivotally coupled to the underside of the ironing surface or frame, whereas the other leg is able to both pivot and slide. In the current embodiment, legs 122 a , 122 b are pivotally coupled, whereas leg 120 can both slide and pivot. In some embodiments, the arrangement may be reversed. The pivotable and slidable arrangement for the legs means that the ironing board can be conveniently folded away. That is, the legs 120 that slide and are locked in the position shown in FIG. 3 for ironing, can be released. The top of the leg 120 can be slid in the direction of arrow 115 . As this happens the legs close in a scissor-like manner, the pivot 130 moving closer to the underside of the ironing surface 110 until the legs lie parallel with ironing surface and frame.
The surface of the ironing board is of an elongate or rectangular shape, and may be formed of a metal base covered by fabric, optionally, the metal base may be supported by the frame as described above.
Although the embodiment described above has three legs, it is also possible that embodiments may incorporate two legs, or more than three legs.
Ironing Surface Shape and Wings
In the currently described embodiment, the ironing surface is based on, but is different to, a normal ironing board shape, that is of an elongate or rectangular shape. The elongate shape has two long sides 131 that are linear along the majority of their length, a short side 132 , and a tip 130 . Adjacent to the short side 132 may be an iron rest 150 for resting the iron when hot or temporarily not in use. In the current embodiment, the tip 130 has a shape comprised of three similar curved portions 133 a , 133 b , 133 c . These three curved portions are preferably identical. Each curved portion has the same length and same curvature. The curvature is at its greatest at the center of the curved portion and decreases further away from the center, becoming linear at the extremes of the curved portion. Each curved portion 133 a , 133 b , 133 c is symmetric, and the three curved portions themselves are arranged symmetrically about the long axis of the ironing surface. Curved portions 133 a , 133 c arranged at the sides of the tip of the board meet the long sides 131 of the board. The decreasing curvature of the curved portion means that portions 133 a , 133 c blend to the linear long sides 131 . Centre curved portion 133 b meets the side curved portions 133 a , 133 c at corners. FIG. 4 shows the tip of the ironing board in detail. This arrangement has been optimised to fit the shoulder yoke of shirts and blouses. The shoulder yoke is the piece of material that forms the shoulders of the shirt. The curvature of the tip of the ironing board is optimised to fit most, if not all, shirts and blouses. The angle between normals to the two side curved portions 133 a and 133 c is preferably between 140° and 155°. In FIG. 4 , 147° is shown as this is a particularly preferred embodiment. Thus, the angle between each of the three curved portions is between 70° and 78°, and is preferably around 73-74°.
FIG. 5 shows how shirts (sometimes known as dress shirts) of any size are placed on the ironing surface 110 . Dashed line 134 a FIG. 5 shows how a child's shirt may be placed on the ironing board, while dashed line 134 b shows an adult's shirt. Both shirts require the same curved portion to fit the shoulder yoke of the shirt, but the child's shirt uses a smaller part of the curved portion 133 b than the adult's. Approximately, and depending on actual size, an adult's shirt will roughly line up so that the middle of the shirt is aligned with the center line of the ironing board, or extend beyond the center line of the ironing board as shown by line 134 b in FIG. 5 . In this way a whole front side (left or right) may be ironed at once without having to reposition the shirt. Conventional ironing boards, such as in FIG. 1 , have a pointed tip. This means only part of the top front, or shoulder yoke, of the shirt is supported at any one time, To iron all of one side of the front of the shirt, the shirt will have to be repositioned many times to realign the tip of the ironing board within the shoulder yoke of the shirt. The ironing board of the current embodiment has a curved tip 130 optimised to fit most, if not all, shirts to allow a front side of the shirt to be ironed at once without requiring repositioning of the shirt. This means ironing of shirts is completed more quickly and easily. The ironing board of the current embodiment is also particularly useful for ironing T-shirts, tunics, nightshirts, jumpers etc, or any other garment that fits across the shoulders and may have a shoulder yoke.
In an alternative embodiment three equal sized linear portions may replace curved portions 133 a , 133 b , 133 c to achieve a similar effect.
The embodiment of FIGS. 3 to 5 may also be provided with attachable wings to further improve the ironing of shirts etc. FIG. 6 shows the approximate shape of a wing 170 . The wing is of a generally triangular shape but is arranged to fit against one of the curved portions 133 a , 133 b , 133 c . Therefore, the wing has a concavely curved edge 171 . The curve of this edge matches that of the curved portion 133 a , 133 b , 133 c of the ironing board of FIGS. 3 to 5 . Thus, the curved edge is symmetric and the curvature is greatest at the center of the curve and decreases towards the extremes of the curve such that at the very extremes the edge is approaching linear. Because the curved portions 133 a , 133 b , 133 c preferably all have the same curved form, the wing 170 will fit against any of these portions. The wing also has a pair of substantially linear edges 172 to make up the generally triangular shape of the wing 170 . The apex where the two linear edges 172 meet may be rounded as shown in FIG. 6 .
FIG. 7 a shows a pair of wings arranged against side curved portions 133 a , 133 c of the tip 130 . The linear edges 172 of the wing meet and extend the curved edge portion 133 b . Thus, the linear edge 172 of one wing, along the curved portion 133 b , to the linear edge of the second wing, makes a continuous smooth line which is optimised to match the shoulder yoke of many shirts and similar garments. In the embodiment shown in FIGS. 6 and 7 a , the angle subtended by the linear edges 172 of the wing is between 60° and 75°, and preferably between 65° and 70°, such as 68° as shown in FIG. 6 . As shown in FIG. 4 , the angle between the two curved portions 133 a , 133 c is between 140 and 155°, and preferably 147°. The symmetry line of the wings 173 are also at this angle to each other, as shown in FIG. 7 a . Based on the above, angle calculations reveal that the angle between the linear edge 172 of one wing, and the linear edge 172 of the other wing is approximately 145°. This is similar to the angle of 147° shown on FIG. 7 a . In some embodiments these angles may equal.
FIG. 7 b shows how a shirt fits to the ironing board. For example, a shirt with buttons and placket down the center of the front of the shirt will align approximately centrally or beyond the center line of the ironing board. The wings partially fill out the ends of the sleeves. The edge, denoted by reference numerals 172 , 133 b , 172 fits in to the shoulder yoke of the shirt. To align the shirt on the ironing board, the shirt should be pulled from one side so that the wing fits into the top of the sleeve. The shirt should also be pulled downwards slightly to fit the curved edge 172 - 133 b - 172 into the shoulder yoke. One half of the front side may be ironed without requiring repositioning of the shirt. Conventional ironing boards would require the shirt to be repositioned many times to be able to completely iron the shoulder yoke and top of the sleeve. For the current embodiment, the placket of the shirt is shown aligned centrally on the ironing board ( FIG. 7 ). However, the actual position of the placket or center line of the front of the shirt will be depend on the size of the shirt. The position of a child's shirt may differ to that of an adult's as shown in FIG. 7 c . For a child's shirt the shoulder yoke may be less curved and fit better to the linear portion which is part of the wing. Hence, the shirt may be placed over the tip and wings at angle to the longitudinal direction of the board, as shown in FIG. 7 c.
As described above, the tip 130 of the ironing board may comprise three identical curved portions 133 a , 133 b , 133 c . FIG. 7 a shows wings attached to two of the curved portions 133 a , 133 c . A wing may also be attached to the curved portion 133 b . FIG. 8 shows the tip of the ironing board with no wings attached ( FIG. 8 a ), a pair of wings attached ( FIG. 8 b ), and a single wing attached ( FIG. 8 c ). The single wing attached to the middle curved portion 133 b provides the ironing board tip with a pointed shape, particularly useful for ironing the seat and tops of the legs of trousers (or pants). The shape of the wings and curved portions are optimised for this purpose. As shown in FIG. 8 c , the linear edges 172 of the wing blend to meet the curved portion of the tip to provide an edge that forms a smooth continuous line.
In an alternative embodiment where the ironing board is provided with three equal linear portions rather than curved portions 133 a , 133 b , 133 c , the wings may be provided with an additional linear edge rather than the concavely curved edge. The additional linear edge will meet the ironing board tip when fitted to the tip.
If the ironing board is provided with three wings then wings may be fitted to all three curved portions of the tip. In total, the tip and wings may be combined to provide an ironing board with eight different shaped tips. Briefly, they are i) no wings, ii-iv) one wing mounted on the left, in the center, or on the right, v) two wings with one mounted on each aide, vi-vii) two wings with one mounted in the center, and one on the left or right side, and viii) three wings, one mounted in each position.
FIG. 9 shows a wing 170 in detail, along with the tip 130 of the ironing board. The wing has an underside 175 and an ironing surface (not shown). When attached to the tip 130 , the ironing surface of the wing meets and is coplanar with the ironing surface 110 of the ironing board to provide a single continuous surface. The wings extend the area of the ironing surface.
The wing 170 is attached to the tip by tongues. There is provided a slidable tongue 177 , and two fixed tongues 176 . The slidable tongue 177 is provided in a slot 178 in the underside of the wing. The slidable tongue 177 is an elongate slidable tab having a rounded knob or button 179 for actuating the tongue 177 . The button is located in the slot 178 and the shape of the slot limits the movement of the tongue 177 . The button may take other shapes or forms. Movement of the button from one end of the slot 178 to the other causes the tongue to move from a retracted position to an extended position.
Fixed tongues 176 are semicircular discs that protrude from the curved edge of the wing. When retracted, the slidable tongue still protrudes a small amount from the curved edge 171 . The amount the slidable tongue 177 protrudes is substantially the same as the amount the fixed tongues protrude. The end of the slidable tongue is semicircular, to match the shape of the fixed tongue. Other shapes of slidable and fixed tongues are possible.
To attach the wing to the tip of the ironing board, the wing should be positioned to locate the tongues in recesses (not shown) in the edge of the tip 110 . The central recess is deeper to accommodate the slidable tongue. The fixed tongues aid with alignment, and the slidable tongue provides most of the support to the wing when fitted to the tip. The tongues may be provided with lugs or ridges (not shown) that fit into keeper notches when the tongues are fully pushed into the recesses in the ironing board tip. The lugs and keeper notches retain the wing securely in the fitted position and prevent it from coming loose. The wing may be removed from the tip by a gentle pulling action to release the lugs from keeper notches. In some embodiments not all of the tongues are provided with lugs. The wings may be fitted to the tip in other ways. For example, the wings may be hinged to the underside of the ironing board, or the wings may slide out of the tip and be retractably stored in the tip.
In the embodiment shown in FIG. 9 , after use the wing may be conveniently stored in the cavity 180 in the underside of the board. The cavity in FIG. 9 is shown at the tip end of the ironing board. A second cavity may be included at the other end of the ironing board, or elsewhere on the underside of the board. The cavity 180 is of a generally triangular shape to match the shape of the wing. That is, the cavity 180 has an outline matching the shape of the wing by having two linear edges and a concavely curved edge. The wing is stored in the cavity by first locating the tongues in recesses in the curved edge of the cavity, and then by pushing the wing against the underside of the board. The cavity is deeper at one end than the other such that the wing protrudes outside the cavity. This allows the user to grasp the wing at one end to remove it from the cavity. As shown in FIG. 9 , the cavity is deeper at the curved end.
The ironing surface of the wings is provided with a material similar to that used for the ironing surface of the board.
Iron Rest
As shown in FIG. 3 , adjacent to the short side 132 of the ironing board 110 , and at the opposite end of the ironing board tip 130 , there may be located an iron rest 150 .
FIG. 10 shows in detail an iron rest according to an embodiment. The iron rest comprises a rotatable turntable 151 and a fixed part 152 . The fixed part supports the turntable and is connected to the ironing surface or the underside thereof. In some embodiments the ironing surface may be formed of a top surface for ironing which is supported by a frame. In such an embodiment, the fixed part 152 of the turntable is connected to the frame. The fixed part 152 is of a shape similar to half an ellipse (cut along the short axis), but may take many other shapes such as rectangular, square etc. The turntable is circular in shape with a rim 151 a around the edge. The fixed part 152 has a circular cut-out in which the turntable 151 rests. The rim 151 a of the turntable rests on the top of the fixed part, but may also have a portion that extends into the circular hole in the fixed part. The rim 151 a provides alignment of the turntable with the hole in the fixed part 152 . Forming chords across the circular rim are pair of flaps 151 b . These flaps have a horizontal part and an inclined part. The inclined part is normally to be used for resting the iron on such that the heel of the iron rests against and below one of the flaps, with the sole plate of the iron touching the other flap, as shown in FIG. 10 d . Since the turntable can rotate, the flaps can be oriented at any angle to the ironing board. FIGS. 10 b and 10 c show the turntable at two positions spaced by 90°, though any position in between may also be achieved. Alternatively to placing the iron on the iron rest as shown in FIG. 10 d , the iron can be placed on the rest end on with the iron pointing vertically upward. The flaps are covered with heat resistant material and hence are not damaged by the heat of the sole plate of the iron.
Advantageously, the turntable 151 can be oriented at any angle. This can help the user in putting the iron on the rest. For example, with the iron rest oriented as in FIG. 10 b or 10 c it may be awkward to put the iron on the rest. When the user is standing at a midpoint along the side of the ironing board, and reaches to put the iron down on rest 150 , the iron will be at an angle to the directions of the turntable shown in FIGS. 10 b and 10 c . Thus, the turntable should be rotated by 20-40° to be in alignment with the direction of the user's arm. Furthermore, the turntable can be rotated to be suitable for use wherever around the ironing board the person stands. For example, some people may not stand at the midpoint of one side but closer to one end. Hence the turntable may be reoriented to suit the user. The turntable may also be reoriented to suit left or right handed users whom may stand on different sides of the ironing board.
In some embodiments the turntable may be mounted on bearings or rollers. In the current embodiment, the rim 151 a retains the turntable by providing surfaces above and below the fixed part which prevent the turntable from being displaced, but allowing it to rotate. The surfaces are bearing surfaces which slide against the fixed part to allow the turntable to rotate. To achieve this arrangement, the rim may be formed of two circular components which fit together to provide a channel to retain the turntable in the circular hole in the fixed part 152 . One of the components sits on the top surface of the fixed part, while the other sits below. Alternatively, a one piece turntable 151 may be provided that has a retainer ridge which locates in a channel in the fixed part 152 . The channel extends all of the way around the side of the circular hole in the fixed part 152 . Hence, as well as retaining the turntable, it also provides a channel in which the ridge slides as the turntable is rotated.
Ironing Surface
The ironing surface 110 of FIG. 3 may be comprised of several components. There may be a base or frame part to which the legs are coupled to. The top surface that is used for ironing may be formed of fabric wrapped around a panel 220 . Such a panel is shown in FIG. 11 . The panel 220 forms the full size of the ironing surface including curved portions at the ironing board tip. The panel 220 has many holes bored through. These holes are to allow steam from the wet or damp garment being ironed to pass out of the garment. The holes also help to reduce weight and material cost. Many holes are provided over each unit of area of the panel, and across the whole of the panel.
The panel 220 is connected to the base or frame of the top by a push and click motion. That is, the panel is provided with feet 225 . Preferably, four feet are provided, two on each of the long sides of the ironing surface spaced towards the ends of each side. The feet comprise an ankle that extends downwards away from the panel. Towards the end of the ankle, the feet extend parallel to the longitudinal direction of the panel. All feet point in the same direction. On the horizontal part of the foot is provided a latch or catch 228 which may consist of a small triangular protrusion facing toward the panel 220 .
FIG. 12 shows the panel fitted to the frame or base of the ironing surface. The frame 230 is provided with an aperture through which the foot 225 can be passed. When the panel is pushed against the frame or base, and slid in the direction of arrow 235 the catch on the foot engages with a notch 240 in the underside of the base. The notch and latch engage to hold the panel on to the base. All feet are arranged to engage with similar notches on the base at the same time.
In FIGS. 11 and 12 the panel or top surface is shown without a fabric covering. FIG. 13 shows in cross-section the panel 220 covered with fabric 232 and fitted to the frame 230 . The panel of the embodiment is covered with fabric 232 prior to fitting to the frame 230 . The fabric 232 is sized to cover the whole panel and is provided with a drawstring 234 around the edge of the fabric. To fit the fabric, it is draped over the top surface, pulled tight across the surface and wrapped a small amount around the edge and underneath the panel. At this point the drawstring 234 can be pulled tight to pull the fabric 232 tightly against the top surface of the panel. The panel can now be clipped into the frame as described above. Because the panel 220 and frame 230 meet towards the edge of the panel, the fabric 232 is gripped tightly between the panel and the frame when the panel is clipped in position by the cooperating notch and catch pairs. Other engaging means to hold the panel to the case may alternatively be used. The gripping arrangement prevents the fabric moving under continued usage of the ironing board. On conventional ironing boards, the fabric is merely tied by a drawstring under the ironing surface. After years of repeated use and continued ironing in the same direction, the fabric begins to migrate in the direction of ironing. After a long time the fabric has moved so much that part of the underlying metal surface of the ironing board may become exposed. The gripping arrangement of the current top prevents the migration of the fabric surface on the top of the board.
Additionally, to avoid puckering or creasing of the fabric top at the corners of the ironing board, the fabric is tailored to fit the board. In particular, the fabric may be stitched or glued to form a pocket around the ironing board tip and along the long sides of the board. Instead of the drawstring described above, the fabric may be held in position by one or more straps across the board. Where the straps meet they may buckle together, tie together, or be adhered to each by the use of Velcro®.
The ability to remove the panel from the top and easily replace the cover also has advantages in matching the ironing board to the household decor. The fabric may be easily changed to match and coordinate with the colours of the room in which it is used.
The fabric used for the ironing surface of the ironing board may be a non-woven cloth produced by matting, condensing and pressing fibers. The fabric provides a smooth non-slip surface over which garments can be placed for ironing. When a garment is in contact with the fabric over a large area, the fabric holds the garment in place. That is the garment will not slide easily as the iron is passed over it. However, when the garment is lifted from the fabric surface, the smoothness of the fabric means that it can be repositioned easily. This ability to both grip the garment but also to allow the garment to be easily moved makes ironing easier and quicker.
Underneath the fabric outer surface which the garment is placed on for ironing may be an insulating layer. The panel underneath may be metal which conducts the heat away rapidly. However, by adding a heat retaining or insulating layer between the fabric and panel heat can be retained close to the garment. The longer heat is retained close to the garment, the longer the de-creasing effect will be. Thus, having run the iron over the surface of the garment, by retaining heat in the surface of the ironing board, the ironing action will not need to be repeated as many times. In a preferred embodiment, the heat retaining material may be a silicon or silicone foam. The silicon or silicone foam is a poor conductor of heat, and the air trapped in the foam will also trap heat. By reducing the number of times the iron needs to be repeatedly passed over a garment, the speed of the ironing task will be increased. Also, because the board retains some heat the iron may not need to be heated as much, and hence may remove creases sufficiently at a lower heat setting. Thus, the reduced iron temperature combined with the increased speed of ironing will reduce the amount of energy required to iron a garment.
Other types of foam may also be used but they must be able to withstand the high temperatures (up to 200° C.) resulting by close contact with the sole plate of an iron and from contact with steam. The foam should also be a closed cell foam such that the steam cannot penetrate through the material. Conventional ironing board covers use open celled foam to allow the steam to pass through (CH 672152). By providing a foam that is not permeable to steam or water, it cannot penetrate through the foam to the metal frame or panel beneath. The use of a steam generator type iron, or an iron that generates large amounts of steam, may result in the water causing the frame or panel to rust, rot, or become coated in lime scale or other deposits. Thus, the use of closed cell foam causes the steam to be reflected or bounced back from the surface of the ironing board, passing back through the garment, such that it evaporates in the air and does not collect on the surface of the ironing board. As well as preventing rusting etc mentioned above, the steam reflected from the surface results in more efficient steam ironing because the steam passes through the garment twice. Additionally, the reflected steam means water does not collect or pool on the ironing surface. Alternatively, an open cell foam can be used provided it is coated with a thin non permeable membrane.
The foam should also be deformable or resilient such that the ironing surface is soft to the touch. When the iron is passed over the ironing surface the foam cushions the path of the iron. The foam is preferably of a light to medium density offering a hardness measured on the OO Durometer scale and preferably in the range 5-40 on that scale. As an alternative measurement of hardness, the compression deflection should be in the range 0.02 to 0.10 MPa.
Thermal conductivities of 0.06 to 0.12 W/m·K are expected, and preferably around 0.0695 W/m·K which is the value for the silicone foam.
Uncompressed densities are in the range 230 to 280 Kg·m −3 (14 to 18 lbs per cubic ft), and preferably around 255 Kg·m −3 (16 lbs per cubic ft). Other specifications for the silicone foam used are given in the table below:
Elongation at break
225%
Tensile Strength
65 Newtons
Compression Recovery
24 hrs @23° C. = 100% after 1 hr
(25% deflection)
24 hrs @100° C. = 95% after 1 hr
72 hrs @150° C. = 85% after 48 hrs
Temperature Range
−40 to +190° C.
Toxicity NES 713 ISS 3
14 MM
Smoke Index NES 711
46
Burn Rate BS4735
0.03 mm per second
The values in this table are measured values from samples tested and some variations from the exact values given above is expected.
Closed cell silicone foam forms a barrier to the steam or water such that it is reflected from the ironing surface. Such foam can also withstand the high temperatures resulting from the ironing process as well as being deformable to cushion the path of the iron.
In an alternative embodiment, the foam can be replaced by other resilient material laminated with a layer through which water or steam cannot penetrate through. For example, a layer of felt can be used to provide the cushioning effect. This is laminated with thin plastic which is preferably flexible. This laminated layer is provided between the rigid panel and fabric sheet. Preferably, the laminated side of the layer faces the rigid panel, but alternatively the laminated side may face the fabric sheet. The latter arrangement prevents water from collecting in the felt and making it damp or wet. As an alternative to felt other types of soft or resilient material may be used. The plastic laminate should be less than half a millimeter thick, and preferably in the range from 10's to 100's μm thick. The felt-plastic is less expensive than silicon foam, and retains the ability to reflect back steam.
Mentioned above are wings 170 , the surface of these wings may also be covered with the same fabric. The wings may also include a heat retaining or insulating material underneath the fabric, such a silicon foam. Other types of heat retaining material may also be used, such as silicon rubber.
Braking Mechanism
FIG. 14 shows a view of the underside of an ironing board of FIG. 3 . This view is a plan view of the ironing board when it is in the upright position. The legs are shown in their open position ready for use of the ironing board. This view shows some of the features of the mechanism used for restraining the legs in the open or closed position. That is, the open position for ironing, and the closed position for storage of the ironing board. Legs 120 , 122 a , 122 b are shown in FIG. 14 . As described above, the legs 122 a , 122 b are coupled by a pivot 270 to the board. Leg 120 meets legs 122 a , 122 b at pivot rod 130 . The top of leg 120 slides in channel 290 . Within case 300 on the underside of the ironing surface there is provided a leg restraint mechanism, or braking mechanism, for holding the leg 120 in the desired position. The mechanism is actuated by handles 280 located in the case 300 .
FIG. 15 shows the braking mechanism in more detail with some of the case 300 removed. FIG. 15 also views the mechanism from the opposite direction to FIG. 14 , that is FIG. 15 is viewed from the top side of the case 300 towards legs 120 , 122 a , 122 b . Hence, the channel 290 shown in FIG. 14 , is shown as a rectangular moulding 290 in FIG. 15 .
In the sides of the channel 290 are provided slots 292 through which a bar is located. This bar 296 also passes through the end of leg 120 . At each side of the channel 290 is provided a hollow guide 294 which has a rectangular cross-section. A slot is also provided in the guide. The slot corresponds with the slot 292 in channel 290 . The slot extends along most of the length of the guide such that along this length the guide has a C-shaped cross-section. Bar 296 extends into the corresponding slot in the guide. A spacer may be mounted on the bar between the channel 290 and guide 294 . Inside the guide 294 , a connecting rod or slide rod 298 couples from the bar 296 to the handle 280 , as shown in detail in FIG. 16 . The connecting rod 298 is mounted to the bar 296 such that the bar may rotate freely without causing rotation of the connecting rod. However, if the leg 120 is moved, the bar will slide also sliding the connecting rod 298 . The connecting rod extends toward the handle 280 , but proximal to the bar 296 the connecting rod has two bends. The bends realign the direction of the connecting rod such that its direction does not project through the axis of the bar but is spaced from it. The purpose of the bends is to position the connecting rod 298 close to the inside surface of the guide 294 for as much of its length as possible.
The handle 280 is connected to an axle 282 passing through the guide 294 . The handle acts as a lever to turn the axle. On the axle is mounted a cam 284 . The cam has an approximately oval shape and is arranged to press against the side of the connecting rod 298 . The handle is biased such that when no pressure is applied by the user, the cam pushes against the connecting rod, the opposite side of which is in turn pushed against the inside wall of the guide 294 , as shown in FIG. 16 b . The bias may be supplied by a lever spring, coiled spring or concentrically coiled spring mounted on the axis. Friction between the inside wall of the guide and the connecting rod, and between the cam and the connecting rod, provides a force to stop the connecting from moving. With the connecting rod restrained at a given position, the legs are also restrained at a given position.
To release the connecting rod 298 to allow the legs to move, the handle is depressed to turn the cam. As the cam turns, the profile of the cam is such that after turning, the part of the cam now closest to the connecting rod has a smaller radius. Thus, the cam no longer pushes the connecting rod against the inside wall of the guide and there is a small gap between the guide and the connecting rod. This is shown in FIG. 16 c . After the handle 280 is released by the user, the bias will turn the cam back to the position shown in FIG. 16 b to hold the connecting rod in position.
As shown in FIG. 14 , the ironing board may be provided with two handles and thus two mechanisms for restraining the leg 120 at given position. The brake mechanism provided on one side of the ironing board is arranged to operate in the opposite direction to the brake mechanism on the other side. The braking mechanism shown in FIGS. 16 a - 16 c is used on a first side of the channel, and a modified mechanism is used on the other side of the channel. The mechanism for the other side also comprises a connecting rod but the bends are formed in the opposite direction to those on the mechanism of FIGS. 16 a - 16 c . In FIGS. 16 a - 16 c the connecting rod passes along the top inner surface of the guide and over the cam. In the mechanism for the other side of the board, the connecting rod passes along the bottom inner side of the guide and underneath the cam, as shown in FIG. 17 b . Thus, for either mechanism, by pushing the cam handle downward, although the cams are rotated in opposite direction, the same braking forces are applied.
In FIGS. 16 a - 16 c , the position of the bar 296 indicates that the legs are retracted closed. When the legs are opened to the position for ironing, the bar will move to the left as shown by the arrow 297 . Whether the legs are open for ironing or retracted for storage, the bias on the cams will turn them to push the cam against the connecting rod and against the inside wall of the guide. Thus in any restrained position, each connecting rod will be held in position by two pairs of frictionally opposed surfaces, i.e. cam to connecting rod, and connecting rod to guide wall. Furthermore, because of the shape of the cam shown in FIG. 16 b , this cam will be more efficient at preventing movement in the direction of the arrow 297 . The alternative arrangement used for the other guide will be more efficient at preventing movement in a direction opposite to the arrow 297 . This is shown in more detail in FIG. 17 . In FIG. 17 a , if a force is applied to the connecting rod to push it to the left, the shape of the cam means that it will push the connecting rod harder against the wall of the guide thereby gripping it tighter. In FIG. 17 b , the opposite is true, if the connecting rod is pushed to the right the cam will push the connecting rod harder against the bottom wall of the guide holding it tighter. Thus, each braking mechanism provides a directional braking action. The two braking mechanisms together provide bi-directional braking mechanism
The braking mechanism described above allows the ironing board to be set to a continuous range of heights for ironing, and not a small number of discrete heights as some prior art devices. In addition, the two braking mechanisms together restrain the iron board at the correct height for the user in a more robust manner than some braking mechanisms. This is especially useful when a heavy steam generator is placed on the ironing board. In addition, the need to push two handles simultaneously to release the brakes provides a safety feature making it difficult for a young child to release both brakes, thereby making the incidence of accidents involving hot irons rarer. An ironing board having the advantage described above may also be provided by using a pair of brake assemblies of the prior art.
In an alternative arrangement, the handles and cams may be configured differently. In the embodiment described above, the handles are squeezed toward the board surface to release the brakes. In the alternative arrangement, the handles are instead pushed towards the edge of the board. The cams are thus arranged to bear on a side surface of the connecting rod rather than the top or bottom surface. Other configurations may also be possible.
The person skilled in the art will readily appreciate that various modifications and alterations may be made to the above described embodiment of ironing board or ironing table without departing from the scope of the appended claims. | Ironing board systems comprising an ironing board having an elongate surface for ironing wherein at an end of its perimeter, said surface for ironing has three adjacent equally spaced arc. The ironing board system includes said ironing board and a wing shaped attachment with an edge having an arc complementary to the arcs of the ironing board. The wing shaped attachment is adapted to detachably couple to said ironing board at any of the three adjacent arcs to extend the ironing surface. The ironing board may comprise a rotatable iron rest, and a braking mechanism for restraining the ironing board in open and closed positions. | 3 |
This application is a division, of application Ser. No. 500,813, filed Mar. 27, 1990 now U.S. Pat. No. 5,135,774.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods and compositions to impart coffee stain resistance to polyamide textile substrates, as well as to the treated substrates themselves. More particularly, the present invention relates to compositions useful in imparting coffee stain resistance to polyamide textile substrates, such as carpets, the compositions comprising either (i) a copolymer selected from the group consisting of a hydrolyzed aromatic-containing vinyl ether maleic anhydride copolymer, a half ester of an aromatic-containing vinyl ether maleic anhydride copolymer, and mixtures thereof, or (ii) an aromatic-containing acrylate copolymerized with an acid selected from the group consisting of acrylic acid and maleic acid.
2. The Prior Art
Polyamide textile substrates, such as carpeting and upholstery fabrics, may be permanently discolored or stained by certain colorants, like food or beverage dyes. It is known to use sulfonated aromatic formaldehyde condensates (a) in a yarn finish, during or after fiber quenching (U.S. Pat. No. 4 680 212), (b) in a dye bath (U.S. Pat. No. 4 501 591), or (c) incorporated into the fiber (U.S. Pat. No.4 579 762), all for the purpose of improving stain resistance of carpet fiber. Use of fluorochemicals in combination with sulfonated aromatic formaldehyde condensates to improve stain and soil resistance is taught in U.S. Pat. No. 4 680 212. Commonly assigned U.S. Ser. No. 101 652, filed Sep. 28, 1987 (International Publication No. WO 89/02949), discloses improved methods, utilizing application of sulfonated aromatic condensates, to enhance stain resistance of dyed nylon carpet fiber. These documents are all hereby incorporated by reference.
In the prior art the stain blocking performance of compositions is typically determined by testing for resistance to FD&C Red Dye 40, which is found in Cherry Kool-Aid® drink product, as well as in other beverages and foods. Those compositions which are effective in enhancing the stain resistance of the substrate to FD&C Red Dye 40 are then described as "stain blockers". Applicants have discovered, however, that not all "stain blockers" which are effective against staining by FD&C Red Dye 40 are effective in enhancing the stain resistance of the substrate to coffee.
The present invention was developed as a consequence of a need for a stain blocker which would be effective in resisting hot coffee stains, preferably in addition to resisting Red Dye 40 stains.
BRIEF DESCRIPTION OF THE INVENTION
This invention is a composition useful in imparting coffee stain resistance to polyamide textile substrates. The composition comprises a copolymer selected from the group consisting of a hydrolyzed aromatic-containing vinyl ether maleic anhydride copolymer, a half ester of an aromatic-containing vinyl ether maleic anhydride copolymer, and mixtures thereof. By the hydrolyzed copolymer, or hydrolysis product, is meant the hydrolyzed copolymer in which some, preferably less than about 25 to 50 percent, of the original anhydride units remain as anhydride. By the half ester is meant the esterification product of the copolymer with a lower alcohol, preferably a C1-C5 alcohol, most preferably isopropyl alcohol, in which some, preferably about 25 to 50 percent, of the original anhydride units remain as anhydride and in which the reacted anhydride units are monoesterified. The copolymer has a weight average molecular weight between about 1,200 and 23,000, preferably between about 1,200 and 15,000, more preferably between about 2,000 and 10,000 and most preferably between about 2,000 and 4,000. The weight average molecular weight is determined by Gel Permeation Chromatography (hereafter "GPC") by comparison with polystyrene standard using a set of Phenogel columns of the 10 micron particle size, covering a range of 50-500 angstroms pore diameter, 300 mm length, 7.8 mm I.D. and with tetrahydrofuran as eluent.
Preferred copolymers can be represented by the formula ##STR1## wherein m is 4 to 100, p is 0.5 m to 0.7 m, X is a moiety of an aromatic compound effective to improve stain resistance, R is alkyl or hydrogen and Z is either --O-- or --O--CH 2 --CH 2 --O--. Preferably m is 2 to 20, X is selected from the group consisting of phenyl, naphthyl, and a partially saturated naphthyl-like ring, and R is C 1 -C 5 . When X is selected from the group consisting of 5,6,7,8-tetrahydro-1-naphthyl and 5,6,7,8-tetrahydro-2-naphthyl, then Z is preferably --O--CH 2 --CH 2 --O-- and R is preferably C 1 -C 3 . When X is selected from the group consisting of 1-naphthyl and 2-naphthyl, and R is C 1 -C 5 , then Z is preferably --O--CH 2 --CH 2 --O--. When X is phenyl, and R is C 1 -C 5 , Z can be either --O--CH 2 --CH.sub. 2 --O-- or --O--, preferably the latter.
The present invention is also a method of imparting improved coffee stain resistance to a polyamide textile substrate comprising treating the substrate with an effective amount of a copolymer selected from those set forth above, i.e., a hydrolyzed aromatic-containing vinyl ether maleic anhydride copolymer, a half ester of an aromatic-containing vinyl ether maleic anhydride copolymer, and mixtures thereof. The preferred copolymers are also as set forth above. The amount of the copolymer added to the substrate ranges from about 0.2 to 3.0, preferably 1.5 to 3.0 percent based on the weight of the substrate. When the substrate is treated with the half ester of phenyl vinyl ether maleic anhydride copolymer, the copolymer preferably is applied to the substrate in an aqueous solution at a temperature ranging from about 20° to 90° C., preferably 50° to 90° C., and having a pH ranging from about 2 to 9. The degree of coffee stain resistance imparted depends on the application pH. The optimum pH depends on the form the material appears to take when applied. If the material appears to be in a dispersion, then application pH can be about 2 to 5; if the material appears to be in solution, then application pH can be about 4 to 9, preferably 5 to 7, most preferably 5 to 6.
This invention is also a coffee stain-resistant polyamide textile substrate, preferably a nylon-6 substrate, having deposited thereon an effective amount of a composition which imparts coffee stain resistance to the substrate. The composition comprises a copolymer as set forth above. When the copolymer is either the half ester or the hydrolysis product of 2-(phenoxy) ethyl vinyl ether maleic anhydride copolymer or of phenyl vinyl ether maleic anhydride copolymer, the substrate has improved resistance to dye fading upon exposure to ozone and light, and does not yellow on exposure to UV light or oxides of nitrogen. When the copolymer is the half ester or the hydrolysis product of phenyl vinyl ether maleic anhydride copolymer, the substrate also has excellent resistance to staining by FD&C Red Dye 40.
In another embodiment, this invention is another composition useful in imparting coffee stain resistance to polyamide textile substrates. This composition comprises an aromatic-containing acrylate copolymerized with an acid selected from the group consisting of acrylic acid and maleic acid. The copolymer has a weight average molecular weight between about 2,000 and 15,000, determined by GPC as previously set forth.
Preferred copolymers for this embodiment can be represented by the formula ##STR2## wherein s is 2 to 50 and t is 2 to 50, X is a moiety of an aromatic compound effective to improve stain resistance, and Z is either --O-- or --O--CH 2 --CH 2 --O--. Preferably, X is selected from the group consisting of phenyl, naphthyl, and a partially saturated naphthyl-like ring. When X is selected from the group consisting of 5,6,7,8-tetrahydro-1-naphthyl and 5,6,7,8-tetrahydro-2-naphthyl, then Z is preferably --O--CH 2 --CH 2 --O--. When X is selected from the group consisting of 1-naphthyl and 2-naphthyl, then Z is preferably --O--CH 2 --CH 2 --O--. When X is phenyl, Z can be either --O--CH 2 --CH 2 --O--or --O--, preferably the latter.
This invention is also a method of imparting improved coffee stain resistance to a polyamide textile substrate comprising treating the substrate with an effective amount of a copolymer selected from those of the second embodiment above, i.e. an aromatic-containing acrylate copolymerized with an acid selected from the group consisting of acrylic acid and maleic acid. The preferred copolymers are as set forth. The amount of the copolymer added to the substrate ranges from about 0.2 to 3.0, preferably 1.5 to 3.0, percent based on the weight of the substrate.
This invention is also a coffee stain resistant polyamide textile substrate having deposited thereon an effective amount of a composition which imparts coffee stain resistance to the substrate. The composition comprises a copolymer of the second embodiment above. It is expected that the substrate will not yellow on exposure to light when the copolymer has the formula ##STR3## wherein s is 2 to 50 and t is 2 to 50, X is phenyl, and Z is either --O-- or --O--CH 2 --CH 2 --O--.
This invention is also a method to apply a polymer, preferably a stain blocker, to the surface of polyamide fibers comprising preparing an aqueous dispersion of microfine polymer beads and causing said beads to contact Said fiber by electrostatic attraction to coat said fiber, then heating the coated fiber. It is preferred that the aqueous dispersion be prepared by dissolving the polymer into a water-soluble solvent, preferably an organic solvent such as acetone, tetrahydrofuran and/or an alcohol, most preferably acetone, followed by injecting the solution into water, whereby the polymer precipitates to form microfine beads which are smaller then about 2 microns. The solvent is then evaporated to leave a dispersion of microfine polymer beads in water. The dispersion has a pH in the range of about 2.0 to 7.0, preferably 2.0 to 3.0. The heating temperature is in the range 70° C. to 200° C., preferably 100° C. to 135° C.
The following terms are defined for use in this specification.
By polyamide is meant nylon 6, nylon 6,6 nylon 4, nylon 12 and the other polymers containing the ##STR4## structure along with the [CH 2 ] x chain. Nylon 6 and 6,6 are preferred.
By textile substrate is meant fiber or yarn which has been typically tufted, woven, or otherwise constructed into fabric suitable for final use in home furnishings, particularly as floor covering or upholstery fabric.
By fiber is meant continuous filament of a running or extremely long length, or cut or otherwise short fiber known as staple. Carpet yarn may be made of multiple continuous filaments or spun staple fiber, both typically pretextured for increased bulk.
DETAILED DESCRIPTION OF THE INVENTION
In the preferred embodiment coffee stain resistance is imparted to a nylon 6 textile substrate, by the hydrolysis product, the half ester, or mixtures thereof, of copolymers made from vinyl ethers and maleic anhydride in which the vinyl ether contains an aromatic ring structure. These copolymers can be represented by the formula ##STR5## wherein m is 4 to 100, p is 0.5 m to 0.7 m, X is a moiety of an aromatic compound effective to improve stain resistance, R is alkyl or hydrogen and Z is either --O-- or --O--CH 2 --CH 2 --O--. X preferably is phenyl, naphthyl or a partially saturated naphthyl-like ring.
The most preferred copolymer is prepared from phenyl vinyl ether and maleic anhydride. These are typically 1:1 alternating copolymers. The hydrolysis product of this copolymer is preferred for resistance to FD&C Red Dye 40 staining, whereas the half ester product, preferably the half isopropyl ester product, of this copolymer is preferred for resistance to hot coffee staining, although each product provides protection against both types of staining. Substrates treated with these most preferred copolymers have the added advantages of not yellowing on exposure to UV light or oxides of nitrogen, and of resistance to dye fading upon exposure to ozone or light.
Alkali metal hydroxides, such as sodium, potassium, and lithium preferably the former, are suitable hydrolyzing agents for making the hydrolysis product. Alcohols, such as the C 1 -C 5 alcohols, preferably isopropyl alcohol, are suitable hydrolyzing agents for making the half ester product of the copolymer.
In the second less preferred embodiment of this invention, coffee stain resistance is imparted to a nylon 6 textile substrate by an aromatic-containing acrylate copolymerized with either acrylic acid or maleic acid. The more preferred copolymers, which can be random or block, made with maleic acid, can be represented by the formula ##STR6## wherein s is 2 to 50 and t is 2 to 50 (this is not necessarily an alternating copolymer), X is a moiety of an aromatic compound effective to improve stain resistance, and Z is either --O-- or --O--CH 2 --CH 2 --O--. X preferably is phenyl, naphthyl, or a partially saturated naphthyl-like ring.
The copolymers of all of the embodiments are readily soluble, even at high concentrations, in water at neutral to alkaline pH; increasing dilution is needed at pH below 6.
The copolymers of this invention can be used as such in treating polyamide textile substrates. They can be applied to dyed, and possibly undyed, polyamide textile substrates. They can be applied to such substrates in the absence or presence of polyfluoroorganic oil-, water-, and/or soil-repellent materials. In the alternative, such a polyfluoroorganic material can be applied to the textile substrate before or after application of the copolymers of this invention thereto. The copolymers can be applied to textile substrates in a variety of ways, e.g. during conventional beck and continuous dyeing procedures. The quantities of the polymers of this invention which are applied to the textile substrate are amounts effective in imparting coffee stain-resistance to the substrate. The amounts can be varied widely; in general, one can use between 0.2 and 3% by weight of them based on the weight of the textile substrate, preferably 1 to 3%, more preferably 1.5 to 3.0%. The copolymers can be applied, as is common in the art, at pHs ranging between 2 and 9.
The copolymers of this invention can also be applied in-place to polyamide carpeting which has already been installed in a dwelling place, office or other locale. They can be applied as a simple aqueous preparation at the levels described above, at temperature described, and at a pH between about 1 and 12, preferably between about 2 and 9. Heating after application is preferred but not necessary for performance. Steam treatment after application does not adversely affect performance.
Staining and test procedures utilized in the Examples were as follows.
TESTING PROTOCOLS
Unless noted otherwise, the fabric samples were a 3.4 g, 2.5 inch wide nylon 6 fabric (plain weave, 12-13 ends/inch×11-12 picks/inch) woven from Allied Type 1189-7B39/2 ply Superba heatset [at 270° F. with presteam] yarn. The fabric was beck dyed into a 1/25 Standard Depth Neutral Grey Shade using C.I. Acid Orange 156, C.I. Acid Red 361 and C.I. Acid Blue 324. The samples were about 3 to 4 inches long.
A. COFFEE
A brew of coffee was prepared using 20 g of Maxwell House Master Blend Auto Drip coffee per 500 mL of water. Thirty milliliters of this coffee solution at 71° C. was dropped from a 12 inch height onto a fabric samples. After one minute the coffee solution was drained and the stain was allowed to remain on the fabric for 4 hours. Then the fabric was rinsed with cold tap water.
1. The coffee stain resistance of early samples was measured by the following technique: A 0-10 scale was used to rate the stain protection, with a score of 0 for a stain similar to stain in a control (no protection) nylon-6 fabric, and a rating of 10 when the stain was not detectable. The rating was done by visual evaluation by, the same panel of evaluators.
2. The coffee stain resistance of later samples was measured using a photovolt single filter colorimeter, as follows. The stain protection of the samples was evaluated using the red (R), green (G), and the blue (B) reflected light values measured with a photovolt single filter colorimeter. The RGB values from the stained, tested samples were referenced to those of a stained control and related in a quantitative form to an unstained fabric sample. The RGB data of each sample represented a color response vector in an RGB tridimensional space. The stain value of each sample was computed from the length of each response vector. The vector length was calculated as follows: Length (i)=SquareRoot (Square(R(i))+Square(G(i))+Square(B(i)) ) where i was the test sample. The stained control was the darkest sample and was represented by the shortest vector. The maximum length vector was derived from the RGB vector of the unstained sample. The stain protection performance of the same is then given by ##EQU1## The stain protection is reported in percent, for comparison with the unstained, untreated fabric sample (at 100%) and the stained control (at 0%).
B. FD&C RED DYE 40
1. Unsweetened cherry Kool-Aid® (0.14 oz) was dissolved in two quarts of water. Thirty milliliters of this solution was poured on a (2.5 inch piece of nylon-6 fabric weighing 3.4 g) from a 12 inch height. After one minute the Kool-Aid was drained and the stain was allowed to remain on the fabric for 4 hours. Then the stain was removed by rinsing the fabric with cold tap water. FD&C Red Dye 40 stain resistance for samples stained in this manner was measured on a 0-10 scale like Technique 1 for coffee above.
2. Unsweetened cherry Kool-Aid (0.14 oz) was dissolved in two quarts of water. Twenty milliliters of this solution were placed in a vial, and a 3.4 g blue grey nylon-6 flat fabric was immersed in this solution with agitation to achieve wetting of the fabric. The fabric was left in contact with this solution for 1.5 minutes and then it was removed and placed in a beaker. The remaining solution was combined with another 5 mL of Kool-Aid solution and it was poured onto the soaked flat fabric from a 12" height. After one minute, the Kool-Aid solution was drained, and the sample was allowed to stand for 4 hrs. At the end of this period the sample was rinsed with cold water and left to dry. FD&C Red Dye 40 stain resistance for samples stained by this procedure was measured using a photovolt single filter colorimeter, like Technique 2 for coffee, above.
C. Colorfastness to light (Yellowing) was measured in accordance with AATCC Test Method 16E-1987, at 40 fading units.
D. Ozone fastness was measured in accordance with AATCC 129-1985.
E. NO 2 fastness was measured in accordance with AATCC 164-1987.
F. Application Methods
1. Solvent Application
A known weight percent of the stain blocker oligomer per weight of fiber (typically 2-4%) was dissolved in 5-10 mL of tetrahydrofuran and diluted to 150 mL with trifluorotoluene. A nylon-6 fabric sample was immersed in half the amount of the above solution, and heated in a steam bath for 15 min. Then the sample was retrieved from the remaining liquid and dried with a hot (40°-90° C.) stream of nitrogen. The remainder of the liquid was mixed with the second half of oligomer solution and this was sprayed over the sample. The treated sample was then dried with a stream of nitrogen, and annealed for 15 min at 105° C.
2. Aqueous Application
(a) The oligomeric stain blocker was dissolved in water at basic pH (e.g. 8-10) and then brought to acidic pH (2-7) With acetic or sulfamic acid. At acidic pH the stain blocker adsorbs onto nylon 6 with a rate of adsorption depending on the temperature and pH of the dispersion/solution.
(b) A 10% solution of the stain blocker in water can be made using NaOH (0.73 eq. NaOH per vinyl ether unit). This solution can be brought to a pH of between 5.5 and 6.5 and diluted with water typically to a 1.3% Stain Blocker solution. Nylon 6 flat fabric is then impregnated with said solution at 65°-75° C. for 1 to 2 min, to give, after squeezing the fabric between two rollers, a take up of 2.8% stain blocker per weight of fabric. The fabric is then annealed at 250° F. for 15 min.
(c) A dispersion is generated by spraying a solution of 1 g of copolymer in 50 mL of acetone into 50 mL of water. The acetone is evaporated to leave an aqueous dispersion of submicron beads. This dispersion is diluted to 1% with water at a pH of 2.0. One gram of nylon 6 fabric is soaked for about 20 minutes in 20 mL of this suspension at 45° C. and then annealed at 135° C. for 15 minutes.
PREPARATION OF STAIN BLOCKERS
Preparation of Saturated Naphthyl Derived Ring Systems by Hydrogenation:
The reduction of the naphthalene rings to yield 5,6,7,8 tetrahydronaphthalene derivatives was done by low pressure catalytic hydrogenation in methanol. The hydrogenations were carried out with the naphthol, naphthoxyethanol, or naphthyl ethyl derivatives. Except for 2-(2-naphthyl) ethanol, the reduction of the first ring was accomplished using 5% rhodium on carbon catalyst (Rh/C), 60 psi H 2 , 60° C., until complete reduction of the unsubstituted ring was observed by gas chromatography (GC). To hydrogenate the 5,6,7,8 position of 2-(2-naphthyl) ethanol it was necessary to use palladium on carbon catalyst (Pd/C), since rhodium is not active
Preparation of Vinyl Ether Derived Stain Blockers: Except for phenyl vinyl ether, the vinyl ether monomers were prepared either by reaction of the appropriate alcohol with2-chloroethyl vinyl ether or by transvinylation using palladium acetate phenanthroline catalyst. These methods are presented below. Phenyl vinyl ether was prepared according to the method of Mizuno et al., Synthesis, 1979, 688, by dehydrohalogenation of phenyl-2-bromoethyl ether with aqueous sodium hydroxide by utilizing the phase-transfer ability of tetra-n-butylammonium hydrogen sulfate. The reaction is exothermic and is completed within 1.5 hours at ambient temperature.
Preparation of 2-(2-Naphthoxy) Ethyl Vinyl Ether) via reaction with 2-chloroethyl vinyl ether):
Three pounds of 2-naphthol were placed in a three necked round bottom flask equipped with an overhead stirrer and a reflux condenser. One liter of dimethyl sulfoxide was used to dissolve the naphthol and to this solution was slowly added 0.8 lb. of NaOH, while keeping the temperature below 50° C. After the addition of NaOH was completed, 1.1 liters of 2-chloroethyl vinyl ether were added slowly while keeping the temperature at 60° C. The reaction mixture was heated at this temperature for 20 hours (the progress of the reaction was followed by GC). After cooling the reaction product was poured into a polyethylene decantation tank and water was added to separate the product. Toluene was added to dissolve the product, and the toluene phase was washed several times with enough 5% NaOH to remove any residual naphthol starting material. The toluene layer was dried with anhydrous Na 2 SO 4 filtered and the toluene was evaporated. The product was identified by GC. A product yield of approximately 85% based on the weight of the naphthol starting material was obtained with this procedure.
Preparation of (2-Naphthyl) Methyl Vinyl Ether (via transvinylation catalyst):
a. Preparation of Palladium Acetate Phenanthroline Catalyst:
Pd(II) acetate, 3.36 g (0.01497 moles), was dissolved in 375 mL of benzene, and filtered through fluted filter paper giving a brown transparent solution. To this was added, dropwise, under nitrogen, a solution of 2.7 g (0.1498 moles) anhydrous 1,10-phenanthroline in 125 mL of benzene. A yellow precipitate resulted, which was filtered off and washed with benzene to obtain 4.7 g of a pale yellow solid.
b. Vinyl Ether Monomer Preparation:
In a three necked round bottom flask equipped with a thermometer, condenser, and magnetic stirrer were added 16 g (0.1 moles) of 2-naphthalene methanol, 200 mL of butyl vinyl ether and 1.0 g of palladium (Pd(II)) acetate phenanthroline. The reaction mixture was stirred overnight while the reaction progress was followed by GC. When conversion was 85% or higher, the catalyst was removed with activated charcoal. After separating the catalyst by filtering, the butanol and the unreacted butyl vinyl ether were removed by distillation. The vinyl ether product was purified to 97%+purity by column chromatography on silica gel using hexane/2% ethyl ether.
Vinyl Ether and Maleic Anhydride Copolymer:
The copolymers were prepared in 1,2-dichloroethane, using VAZO 67, 2,2'-azo-bis-(2 methylbutyronitrile) as initiator, and butanethiol or dodecanethiol as the chain transfer agent to control the degree of polymerization.
Preparation of 2-(2-Naphthoxy) Ethyl Vinyl Ether/Maleic Anhydride Copolymer:
2-(2-naphthoxy) ethyl vinyl ether (20.0 g, 0.09524 moles), and maleic anhydride (9.33 g, 0.09524 moles) were dissolved in (155 mL) dichloroethane. The solution was placed in a three necked round bottom flask equipped with a thermometer, a condenser, and nitrogen inlet, and purged with nitrogen for half an hour. Then VAZO 67 (0.61 g, 0.003175 moles) and butanethiol (4.08 mL, 0.93799 moles) were added under nitrogen. The polymerization was carried out at 60° C. for 24 hrs or longer until complete monomer conversion. The polymer was isolated by precipitation in hexane.
Preparation of the Isopropyl Monester of 2-(2-Naphthoxy) Ethyl Vinyl Ether/Maleic Anhydride Copolymer:
The anhydride copolymer was dissolved in the minimum amount of tetrahydrofuran. The solution was diluted with toluene, and then isopropanol. The solution was refluxed, until 50-75% of the monoester was formed as determined by infra red (IR) or by carbon 13 nuclear magnetic resonance ( 13 C NMR). The copolymer was recovered by precipitation. The average molecular weight of the copolymer was determined by gel permeation chromatography (GPC).
Acrylate Derived Stain Blockers:
The acrylate monomers were prepared by the reaction of the corresponding alcohols with acryloyl chloride as described below.
Preparation of 2-(2-Naphthoxy) Ethanol:
The reaction set-up consisted of a three necked round bottom flask, equipped with a thermometer, condenser and a mechanical stirrer, and a dropping funnel. 2-Naphthol, 100 g (0.6936 moles), was dissolved in 60 mL of dimethyl sulfoxide. Sodium hydroxide, 27.7 g (0.6936 moles), was carefully added to the solution. Then 2-chloroethanol, 61.4 g (0.7629 moles), was slowly added, keeping the reaction temperature at 80° C. The reaction was followed by GC. After >>80% conversion was achieved, the reaction was worked-up by adding toluene and extracting the unreacted naphthol with 5% aqueous NaOH. The product was then recrystallized in ethanol or distilled under vacuum (70-80% yield).
Preparation of 2-(2-Naphthoxy) Ethyl Acrylate:
In a round flask provided with an overhead stirrer, condenser, and addition funnel 2-(2-naphthoxy) ethanol, 40.0 g (0.2127 moles), was added and the system was swept with nitrogen for 15 minutes, then a dry tube was placed, in the outlet of the condenser to prevent moisture from getting into the system. Acryloyl chloride, 21.1 g (0.2340 moles),was added dropwise, and the solution was stirred overnight. The solution was worked-up by extracting the HC1 formed with water, evaporating the solvent and purifying the product by distillation (84% yield). Further purification by column chromatography was necessary.
The polymerization was carried out under nitrogen, using 1,2-dichloroethane as the solvent, VAZO 67 as the initiator, and butanethiol as a chain transfer agent to control the degree of polymerization. A typical polymerization is described below.
Homopolymerization of 2-(2-Naphthoxy) Ethyl Acrylate:
The monomer, 3.0 g, was dissolved in 1,2 dichloroethane. The system was purged with nitrogen, and VAZO 67, 30.6 mg (0.0002065 moles), and butanethiol, 0.53 mL (0.004942 moles), were added. The polymerization was carried out at 60° C. until total monomer conversion. The polymer was precipitated in hexane.
Preparation of 2-(2-Naphthoxy) Ethyl Acrylate/Maleic Diacid Copolymer:
2-(2-Naphthoxy) ethyl acrylate (3.0 g, 0.01239 moles) and maleic anhydride (1.21 g, 0.01239 moles) were dissolved in 20.7 mL of dichloroethane. The solution was placed in a 100 mL three-necked round bottom flask equipped with a thermometer, condenser, stirring bar, and nitrogen inlet, and purged with nitrogen for half an hour. Then VAZO 67 (0.159 g, 0.000826 moles) and butanethiol (0.028 g, 0.000309 moles) were added under nitrogen. The polymerization was carried out at 60° C. for 24 hours until complete monomer conversion. The dichloroethane was then evaporated, a brown gummy solid was redissolved in tetrahydrofuran (15 mL) and added dropwise to 75 mL of ethanol to give once filtered, 1.86 g of a light brown solid. 1.20 g of this light brown solid, 20 mL of tetrahydrofuran, 3.0 mL H 2 O, and 0.10 g of p-toluene sulfonic acid were added to a 50 mL single necked round bottom flask and the reaction was run at 80° C. with stirring overnight. IR analysis then indicated that only about 20% of the anhydride remained, and the main peak came at 1700 CM- 1 characteristic of a carboxylic acid group. The brownish solution was precipitated in 100 mL of hexane to give 1.5 g of a light brown solid (30-40% yield). The average molecular weight of the copolymer was determined by GPC.
EXAMPLE 1
With reference to Table 1, the copolymers listed were applied to a nylon 6 fabric sample by the solvent application method. These copolymers, which were each about 50-75% isopropyl monoester, had a number average molecular weight of about 5000-10,000. The fabric samples were tested for coffee stain resistance by Technique 1 set forth above, the 0-10 stain protection rating wherein 0 represents no protection and 10 represents complete protection. Data are presented in Table 1.
EXAMPLE 2
With reference to Table 2, the copolymers listed were applied to a nylon 6 fabric sample by the solvent application method. These copolymers, which were each 50-75% isopropyl monoester, had the number average molecular weights set forth in Table 2. The fabric samples were tested for coffee stain resistance by Technique 1 previously set forth. Data are presented in Table 2.
EXAMPLE 3
With reference to Table 4, the copolymers listed were applied to a nylon 6 fabric sample by the solvent application method. These copolymers, which were each 50-75% isopropyl monoester, had a number average molecular weight of about 5000-10,000. These fabric samples were then tested for lightfastness using AATCC method 16E-1987. Data are presented in Table 4.
EXAMPLE 4
With reference to Table 5, the copolymers listed were applied to a nylon 6 fabric sample via the solvent application method, modified as follows: the copolymer/trifluorotoluene solution was sprayed onto the sample to achieve about 3% of the copolymer based on the weight of the substrate. These copolymers, which were each about 50-75% isopropyl monoester, had a number average molecular weight of about 5,000-10,000. The fabric samples were tested for coffee stain resistance by Technique 2 set forth above, using a photovolt single filter colorimeter.
EXAMPLE 5
Best Mode
Fifteen grams of phenyl vinyl ether/maleic isopropyl monoester copolymer were added to 119 g of water to make a slurry. Then 15.6 g of a 10% NaOH aqueous solution were added, and the mixture was heated to 75° C. for 20 min. The solution was then allowed to cool to room temperature. A 10% w/w clear golden solution was obtained and the pH of this solution was around 6.0 to 6.5. This copolymer solution was diluted with water to a 1.32% w/v and the pH was adjusted to 5.8 with sulfamic acid. A grey nylon 6 flat fabric (3.4 g), was immersed in 50 g of the 1.32% weight by volume (w/v) aqueous copolymer solution at 70° C. for 3 minutes. The flat fabric was wrung out to a 237% weight pick-up, which resulted in a 3.1% polymer add-on per weight of fiber (wof). The flat fabric was then heated at 220°-250° F. for 20 minutes.
A sufficient number of fabric samples were prepared to test separately for resistance to coffee staining, resistance to FD&C Red Dye 40 staining, lightfastness, ozone fastness and resistance to the action of oxides of nitrogen. Data are presented in Tables 6 and 7(sample 22).
For comparison, untreated control samples were stained with coffee and cherry Kool-Aid, respectively. These control samples and a blank are presented in Table
EXAMPLE 6 (COMPARATIVE)
Twelve and a half grams of deionized water were added to 20 g of a styrene maleic anhydride copolymer (commercially available from Aldrich Chem. Co., Catalog No. 20060-3, 1600 weight average molecular weight, white solid, 1:1 ratio styrene to maleic anhydride) in a 250 ml three-necked round bottom flask, and stirred with an overhead stirrer to make a white slurry. Then 22.5 g of a 30% NaOH aqueous solution were added dropwise so as not to exceed 40° C. temperature in the flask. The flask was then heated to 70° C. and stirred for three hours. Then 11.6 g of deionized water were added to make a 30% concentrated solution. This solution was then allowed to cool to room temperature. A viscous, light yellow solution was obtained, and the pH of the solution was about 9.9. This copolymer solution was diluted with water to a 1.32% w/v and the pH was adjusted with acetic acid to 5. A blue-grey nylon-6 flat fabric (3.4 g, about 4 inches×2.5 inches) was immersed in 50 g of 1.32% w/v aqueous copolymer solution at about 85° C. for 5 minutes. The solution container was shaken once every minute. The flat fabric was wrung out to achieve about a 2.9% polymer add-on per weight of fabric. The sample was dried at about 200° F. for 25 minutes, without rinsing first since this adversely affected performance. A sufficient number of samples were prepared to test for coffee stain protection and FD&C Red Dye 40 stain protection using a photovolt single filter colorimeter. Data are presented in Table 6.
EXAMPLE 7
5.4 g phenyl vinyl ether/maleic anhydride were added to 13.2 g of water (in a 250 mL 3-necked round bottom flask) t0to make a slurry. Then 8.44 g of a 20% , NaOH aqueous solution were added, and the mixture was heated to 75° C. for 2.5 hours with stirring by overhead stirrer. The solution was then allowed to cool to room temperature. A viscous, orange solution was obtained with a pH of about 9. This copolymer solution was diluted with water to a 1.32% w/v, and the pH was adjusted to 5 using a 5% acetic acid/water solution. Fabric samples were made as in Example 5 except that the polymer add-on per weight of fiber was about 3%. Samples were tested for stain resistance (%) to coffee and FD&C Red Dye 40, respectively, using a photovolt single filter colorimeter. Data are presented in Table 6 (Sample 24).
EXAMPLE 8
Example 7 was repeated, except that the pH was adjusted to 5.8. Data are presented in Table 6 (Sample 25).
EXAMPLE 9
0.1 g of phenyl vinyl ether/maleic isopropyl monoester (number average molecular weight 4500) stain blocker was dissolved in 5 mL of 1% NaOH solution to make a 2% polymer in water solution, which was then diluted to 0.2% polymer in water. This diluted solution was then sprayed, using a thin layer chromatography (TLC) sprayer onto 500 mL of water at pH 2.0 (sulfamic acid), under constant stirring at 40° C. while keeping the overall pH at 2.0. This created a dispersion of the polymer in water. 2.5 g of a nylon-6 fabric were immersed in the polymer dispersion at 40° C. for 2 hours. The dispersion was not completely exhausted. The coated fabric was dried in air and annealed at 120° C. for 30 minutes. Coffee stain test, Technique 1, gave a rating of 8.
EXAMPLE 10
A solution of 1 gram of phenyl vinyl ether/maleic isopropyl monoester copolymer in 50 mL of acetone was sprayed into 50 mL of water. The acetone was evaporated to leave an aqueous dispersion of submicron , beads. This dispersion was diluted to 1% with water at pH 2. One gram of nylon-6 fabric was soaked in 20 mL of this suspension at 45° C. for 20 minutes and then annealed at 135° C. for 15 minutes. The resulting fabric sample showed good protection against coffee staining according to Technique 1.
EXAMPLES 11-12
Example 7 was repeated in Example 11 with the following modifications: The copolymer solution in which the fabric was immersed was at 75° C. rather than 70° C., and the flat fabric was heated at 90° C. for 20 minutes. The fabric was tested for stain resistance (%) to FD&C Red Dye 40 using a photovolt single filter colorimeter-protection was 99.3%.
Example 12 was a repeat of Example 11except that the fabric was allowed to air dry at room temperature, about 25° C., i.e., there was not heating step. Protection level was 92.0%.
This set of examples demonstrates that the hydrolysis product of phenyl vinyl ether/maleic anhydride copolymer can be applied to an installed carpet to yield excellent protection against FD&C Red Dye 40 stains. The product can be applied by soaking the installed carpet with the product followed by air drying of the carpet. There is no need to provide extra heat in drying the carpet or as an added treatment to achieve good stain protection.
DISCUSSION
Applicants have found that coffee stain protection can be achieved when the vinyl ether monomer of the vinyl ether/maleic anhydride copolymer contains an aromatic ring (phenoxy, naphthyl or a partially saturated naphthyl-like ring). With reference to Table 1, it can be seen that straight chain hydrocarbons (Samples 3 and 2) provide little to no protection, but when the side chains include an aromatic ring system (Samples 4-6, 8-9, 11), there is good protection.
Applicants have also found that the aromatic , ring of the copolymer must be bound to an oxygen as part of the chain connecting the ring to the polymer backbone. See samples 22-25 in Table 6 which demonstrate the superior coffee stain resistance of Samples 22,24 and 25 versus Sample 23. Also see Table 5, Samples 4 and 21.
The importance of an oxygen being part of the chain binding the aromatic ring of the copolymer to the polymer backbone is also seen with FD&C Red Dye 40 Stains. See Table 6 wherein Comparative Sample 23 does not have such an oxygen and has inferior performance to both of Samples 22 and 24 of the present invention.
Coffee stain protection was tested with coffee at a temperature of 71° C., i.e., with hot coffee. The samples in Table 3 demonstrate that having a glass transition temperature and/or a melt temperature greater than 71° C. is not required of the copolymer in order to achieve hot coffee stain protection.
While vinyl ether/maleic anhydride copolymers are considered the best mode of practicing this invention, it was also found that acrylate/maleic anhydride copolymers offer coffee stain protection; homoacrylates, however, did not protect against coffee stains. See Table 2. And although the protection offered by the copolymer of Sample 17 is only 4, this sample is included as part of the present invention since it was not an optimized structure; the monomers' ratio could probably be varied to provide improved performance.
The naphthoxy containing copolymers yellowed upon exposure to ultra violet (UV) light even when the oxygen in the naphthoxy or 5,6,7,8-tetrahydro-2-naphthoxy ring of the above mentioned copolymers was etherified. See Table 4. A phenoxy ring linked from the phenoxy oxygen (phenyl--O--) to the vinyl ether oxygen (O--CH═CH2 by a CH2CH2 group: (phenyl--O--CH2CH213 OCH═CH2) gave stain protection against coffee, although much lower than the protection given by the same naphthoxy arrangement (compare Samples 9and 4 in Tables 1 and 4); however it , had the advantage that it did not yellow. This was surprising because the 5,6,7,8 tetrahydro-2-naphthoxy ethyl vinyl ether/maleic isopropyl monoester (Sample 6, Table 4), which could be considered an etherified dialkyl substituted phenoxy derivative, did yellow upon exposure to UV light.
A preferred stain blocker was obtained when a phenyl ring was linked directly to the vinyl ether oxygen. This arrangement with the oxygen from the phenoxy ring being the vinyl ether oxygen, gave the best combination of coffee stain protection with no yellowing upon exposure to UV light or oxides of nitrogen. See Tables 4, 5, 6 and 7.
The half ester, namely the half isopropyl ester of the vinyl ether/maleic anhydride copolymers gave better coffee stain protection than the hydrolysis product (see Table 6). This is in contrast with FD&C Red Dye 40 protection where both the half ester and the hydrolysis product of the anhydride copolymer gave excellent protection. Furthermore, each can be applied to achieve this protection as easily as soaking the carpet in an aqueous solution thereof, steaming the carpet if desired, and allowing to air dry.
It is possible that optimum performance against both types of stains may be obtained with a combination of the half ester and the hydrolysis product.
Effect of Molecular Weight on Performance
Using the compound of the invention, 2-(1-naphthoxy) ethyl vinyl ether/maleic isopropyl monoester copolymer, (50-75% monoester), of the following molecular weights, stain protection was evaluated as shown:
______________________________________Mol. Wt. × 10.sup.3 Stain Protection*______________________________________less than 4.5 7 4.5 9-10 7.9 8-9 23 7-8______________________________________ *by Tecnhique 1 for Coffee Stains, above.
It is believed that the other compounds of this invention will show very similar results.
TABLE 1______________________________________ Coffee StainSample Copolymer Protection______________________________________1 Control 02 Decyl vinyl ether/Maleic 0(comparative) anhydride3 Docosyl vinyl ether/Maleic 4-5(comparative) isopropyl monoester4 2-(2-Naphthoxy) ethyl vinyl 9-10 ether/Maleic isopropyl monoester5 2-(1-Naphthoxy) ethyl vinyl 9-10 ether/Maleic isopropyl monoester6 2-(5,6,7,8-Tetrahydro-2- 8-9 naphthoxy) ethyl vinyl ether/Maleic isopropyl monoester7 2-(2-Decahydro naphthoxy) 2(comparative) ethyl vinyl ether/Maleic isopropyl monoester8 Phenyl vinyl ether/Maleic 9-10 iospropyl monoester9 2-(Phenoxy) ethyl vinyl 8-9 ether/Maleic isopropyl monoester10 2-(4-Cyclohexyl phenoxy) 6-5 ethyl vinyl ether/Maleic isopropyl monoester11 2-(2-Naphthyl) ethyl vinyl 7-8 ether/Maleic isopropyl monoester12 (2-Naphthyl) methyl vinyl 0(comparative) ether/Maleic isopropyl monoester______________________________________
TABLE 2______________________________________ Coffee Stain Mol. Pro-Sample Copolymer Wt tection______________________________________13 2-(2-Naphthoxy) ethyl vinyl 4.8 × 10.sup.3 9-10 ether/Maleic isopropyl monoester14 Poly 2-(2-Naphthoxy) ethyl 2.9 × 10.sup.3 2(comparative) acrylate15 Poly 2-(2-Naphthoxy) ethyl 7.7 × 10.sup.3 2(comparative) acrylate16 Poly 2-(2-Naphthoxy) ethyl 14 × 10.sup.3 2(comparative) acrylate17 2-(2-Naphthoxy) ethyl 6 × 10.sup.3 4 acrylate/Acrylic acid18 2-(2-Naphthoxy) ethyl 6 × 10.sup.3 7-8 acrylate/Maleic acid______________________________________
TABLE 3______________________________________ Coffee StainSample Copolymer T.sub.g.sup.1 (°C.) T.sub.m.sup.2 (°C.) Protection______________________________________6 2-(5,6,7,8, 98 -- 8-9 Tetrahydro-2- naphthoxy) ethyl vinyl ether/Maleic isopropyl monoester4 2-(2-Naphthoxy) ethyl 50 -- 9-10 vinyl ether/Maleic isopropyl monoester10 2-(4-Cyclohexyl- 60 126 6-5 phenoxy) ethyl vinyl ether/Maleic iso- propyl monoester______________________________________ .sup.1 Glass transition temperature. .sup.2 Melt temperature.
TABLE 4______________________________________ Yellowing (40Samples Copolymer AATCC Fading Units)______________________________________8 Phenyl vinyl ether/Maleic No yellowing isopropyl monoester9 2-(Phenoxy) ethyl vinyl No yellowing ether/Maleic isopropyl monoester4 2-(2-Naphthoxy) ethyl vinyl Yellowing ether/Maleic isopropyl monoester11 2-(2-Naphthyl) ethyl vinyl Yellowing ether/Maleic isopropyl monoester6 2-(5,6,7,8-Tetrahydro-2- Yellowing naphthoxy) ethyl vinyl ether/Maleic isopropyl monoester19 2-(4-Methyl-2-naphthoxy) Yellowing ethyl vinyl ether/Maleic isopropyl monoester20 2-(5,6,7,8-Tetrahydro-2- Yellowing naphthyl) ethyl vinyl ether/Maleic isopropyl monoester______________________________________
TABLE 5______________________________________ Coffee Stain Protection (%) Technique 2 DetergentSample Copolymer Water Rinse Rinse*______________________________________4 2-(2-Naphthoxy ethyl 55.8 74.3 vinyl ether)/Maleic isopropyl monoester21 2-(1-Naphthyl ethyl 33.5 -- vinyl ether)/Maleic isopropyl monoester8 Phenyl vinyl ether/Maleic 64.2 89.4 isopropyl monoester9 Phenoxy ethyl vinyl ether/ 54.2 -- Maleic isopropyl mono- ester______________________________________ *5 minute wash with AllIn-One detergent solution (7.5 g/l) at 60° C.
TABLE 6______________________________________ Coffee Stain Protection (%) FD&C Red Dye Water Detergent No. 40Sample Copolymer Rinse.sup.1 Rinse.sup.2 Protection (%)______________________________________Blank.sup.3 -- 100 -- 100Coffee -- 0 -- --StainedControlCherry -- -- -- 0Kool-AidStainedControl22 Phenyl vinyl 69 90 93 ether/Maleic isopropyl monoester23* Styrene/Maleic 18.3 -- 77.9 acid.sup.424 Phenyl vinyl 32.7 -- 99.3 ether/Maleic acid.sup.525 Phenyl vinyl 21.1 -- -- ether/Maleic acid.sup.6______________________________________ *Comparative .sup.1 As set forth in Coffee Testing Protocol. .sup.2 Five minute wash with Allin-one detergent solution 7.5 g/l at 60° C. .sup.3 The blank was an untreated, unstained sample. It is given a value of 100% for protection since it is what a sample with 100% protection would look like. .sup.4 Hydrolysis product of the anhydride copolymer, number average molecular weight about 1600. .sup.5 Hydrolysis product of the anhydride copolymer, aqueous application at pH 5. .sup.6 Hydrolysis product of the anhydride copolymer, aqueous application at pH 5.8.
TABLE 7______________________________________ Gray Scale Rating* Oxides of Ozone Nitrogen Lightfastness.sup.1 Fastness.sup.3 FastnessSample Copolymer (40 SFU.sup.2) (3 cycles) (1 cycle).sup.4______________________________________Control -- 3 1 322 Phenyl vinyl 4 3-4 3 ether/Maleic isopropyl monoester______________________________________ .sup.1 AATCC 16E1987. .sup.2 AATCC Standard fading unit. .sup.3 AATCC 1291985. .sup.4 AATCC 1641987. *AATC Evaluation Procedure 1 | The present invention provides methods and compositions to impart coffee stain resistance to polyamide textile substrates such as carpets. The compositions comprise either (i) a copolymer selected from the group consisting of a hydrolyzed aromatic-containing vinyl ether maleic anhydride copolymer, a half ester of an aromatic-containing vinyl ether maleic anhydride copolymer, and mixtures thereof, or (ii) an aromatic-containing acrylate copolymerized with an acid selected from the group consisting of acrylic acid and maleic acid. The coffee stain-resistant polyamide textile substrates made are also part of the invention. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to vehicle mounted satellite antennae. More particularly, the invention relates to a low profile antenna which can be integrated into or installed horizontally on top of a roof of a vehicle including the integration into a moonroof or sunroof.
2. Related Art
It has long been known how to mount a satellite antenna (dish) atop a vehicle for purposes of communicating with a geostationary or other type of satellite. The initial applications for mounting a satellite dish on a vehicle were military communication and remote television news broadcasting. Consequently, the first methods of mounting a satellite dish included a telescoping mast which was hingedly coupled to the vehicle. When the vehicle was in motion, the mast would be retracted and folded with the satellite dish lying end up on the roof or a side wall of the vehicle. The dish would be deployed only when the vehicle was stationary. Such a deployable vehicle mounted satellite dish is disclosed in U.S. Pat. No. 5,961,092 to Coffield. Until recently, no vehicle mounted satellite antennae were operable while the vehicle was in motion. The relatively large size of a conventional satellite dish antenna presents significant wind resistance if deployed on a vehicle in motion. This wind resistance adversely affects the operation of the vehicle and subjects the satellite dish to potential wind damage. Moreover, satellite dishes must be accurately aimed at a satellite within a relatively narrow aperture or “look window”. In order to operate a satellite dish mounted on a vehicle in motion, it would be necessary to constantly re-aim the dish in order to maintain communication with the satellite.
Recently, satellite antennae have been developed which may be deployed on a vehicle and operated while the vehicle is in motion. Such antennae are disclosed in U.S. Pat. No. 5,398,035 to Densmore et al., U.S. Pat. No. 5,982,333 to Stillinger, and U.S. Pat. No. 6,049,306 to Amarillas. These antenna systems generally include a satellite antenna of reduced size and a solenoid system for aiming the antenna. The solenoid system is coupled to a feedback system and/or vehicle motion detectors in order to automatically re-aim the antenna as the vehicle is in motion. In order to reduce aerodynamic drag and protect the antenna from wind damage, an aerodynamic radome is often used to cover the antenna.
Vehicle mounted satellite antennae which are operable while the vehicle is in motion, can provide one-way or two-way satellite communications. Some applications for such antennae include satellite television reception, telephony in remote locations where cellular telephone service is unavailable, and broadband data communications. The application of television reception may be advantageously applied in common carrier transportation such as long distance buses, in recreational vehicles including boats, and in the rear seats of family mini-vans. The application of remote telephony may be applied in the same situations as well as in various other governmental and commercial settings. The application of broadband data communication may also be applied in many personal, commercial, and governmental settings.
Broadband satellite communication, such as television reception or broadband data communication requires a high gain antenna with high cross-polarization isolation and low signal sidelobes. Satellite antenna gain is proportional to the aperture area of the reflector. Stationary satellite antennae typically utilize a circular parabolic reflector. Reflector type of satellite antennae designed for use on a moving vehicle is difficult to achieve low profile. In order to maintain gain, these low profile antenna are short but wide so that the overall aperture area is kept high. However, this design strategy only works to a point. When the width to height ratio exceeds a certain value such as 2, the efficiency of the antenna is adversely affected. The presently available vehicle mountable dish reflector type of satellite antennas, for commercial and personal use, are no shorter than approximately fifteen inches in height. A mobile satellite antenna produced by Audivox Corp. (MVSTS Satellite TV System) provides four circular Casegrain dish reflector antennas positioned along a horizontal axis perpendicular to the direction of antenna aiming. The signals received by the four dish reflectors are combined in phase to achieve aggregate antenna gain. Since the signal arriving at the phase centers of the four reflectors with the same propagation delay, no phase shifters are required for this mobile satellite antenna. The use of four reflector dishes allow the width to height ratio to be stretched further, while maintaining the antenna efficiency. The overall height of this antenna including radome is approximately 9.5 inches, considerably reduced from the single reflector type of dish antenna. Another mobile satellite antenna produced by Titan corporation (DBS-2400 Low Profile Ku-Band Antenna System) uses four hemisphere Luneberg lens antennas positioned on top of a ground plate along a horizontal axis perpendicular to the direction of the antenna aiming. The signals received by four Luneberg lens antennas are combined. The use of the ground plate to create an image of the hemisphere antenna reduces the height of the Luneberg lens by half, to approximately 5 inches (including radom). Another approach described in U.S. Pat. Nos. 6,657,589 and 6,653,981 to Wang et al., is a linear cylindrical Casegrain reflector antenna with line source. Such antenna profile is also limited to approximately 5 inches without elongating the antenna length prohibitively. A common drawback of the antennas described above is that two dimensional mechanic movement and control is required to aim the antenna toward satellite. This makes the mechanic design complicated and reduces the reliability of the antenna system. Another drawback of these types of antennas is that the height of the antenna is still too large for esthetically mounting on top of the roof of the commercial vehicles such as mini-van or SUV (Suburban Utility Vehicle). Further, the Lunberg lens antenna approach is heavy and expensive.
Another approach for implementing the mobile satellite antenna is to employ a phased array antenna having a large number of antenna elements. An antenna aiming in the azimuth and elevation directions is achieved by passing the received signal from each antenna element through a phase shifter. The phase shifter rotates the phases of the signals received from all antenna elements to a common phase before they are combined. While such antennas can be implemented with a very low profile, the large number of microwave processing elements such as amplifiers and phase shifters used in the electronic beam forming network results in high implementation cost, preventing mass volume commercial use. One of such antenna was published by V. Peshlov et al. of Sky Gate BG, IEEE 2003, Phased-array antenna conference.
U.S. Patent Application Nos. 2003/0083063, 2003/0080907 and 2003/008098 describe an antenna mounted on a horizontal platform, which is rotatable to adjust the antenna beam in the azimuth direction driven by a motor, and is also capable of steering the antenna beam in the elevation direction through an electronic beam forming network.
Waveguide antennas are typically less than one wavelength in height and provide signal combining along the waveguide longitudinal axis. Many forms of waveguides can be used for microwave energy transmission. Rectangular waveguides have currents flowing on its interior wall and interrupting those currents by cutting through the waveguide wall can cause radiation into the exterior. It is well known, and used, that a radiating aperture is achieved when that aperture is approximately one-half free space wavelength long and one twentieth of a wavelength wide is cut through the broad wall of that waveguide. The aperture is widely described as a “slot” through the waveguide wall. Locating such a slot at various positions on the waveguide wall achieves varying degrees of excitation of microwave fields emanating from the slot. The microwave fields from the simple slot are characterized as being linearly polarized microwave fields.
Many applications for field radiating structures require that the radiated fields have the property of being circularly polarized. A widely used technique for producing a circular polarized radiating element is the cutting of a pair of slots through the broad wall of a rectangular waveguide. The two slots are typically caused to cross each other at ninety degrees to each other, and at the center of each slots length. Further, the crossed slot is normally placed on a line that is parallel to the waveguide axis and is a distance of approximately one quarter of the waveguide width away from the waveguide axis.
U.S. Pat. No. 3,503,073 to James Ajioka et al., and subsequently in IEEE Transaction On Antenna and Propagation, March 1974, describes using a dual polarized slot radiators in bifurcated waveguide arrays. The radiating element is a pair of crossed slots in the narrow wall of a bifurcated rectangular waveguide that couples even and odd modes. One linear polarization is excited by the even mode, and the orthogonal linear polarization is excited by the odd mode. Alternatively, one circular polarization can be excited through one of the pair of waveguides, whereas, the other circular polarization can be excited through another waveguide in the pair. The above-described antenna design approach has the drawback of unequal propagation velocities of the even and odd mode within the waveguide which causes the even and odd beam to point at different direction. In order to equalize the two group velocities, very narrow compensating slits within the waveguide wall are used, which reduces the waveguide bandwidth and significantly complicates the manufacturing complexity.
Another antenna described in IEEE Transaction of Vehicular Technology, January 1999 by K. Sakakibara et al., employs X-shaped slot located in the broadwall of a rectangular waveguide, approximately halfway between the center line and the narrow wall, to form a two-beam slotted leaky waveguide array. The broad side width of rectangular waveguide is approximately half the waveguide, and the cross slot center is offset from the center of the waveguide toward the sidewall by approximately 90 mil. The slot spacing along the waveguide is 0.874 inch. Such waveguide spacing can result in grating lobe when the beam is steered to different elevation angle. At higher elevation angle, the grating lobe becomes comparable in strength to the main lobe, thereby reduces the antenna gain. A right-hand circular polarization can be achieved by feeding the waveguide from one end, whereas a left hand circular polarization can be achieved by feeding the waveguide from the opposite end. One disadvantage of this antenna is that the beam direction of the right-hand polarization antenna is different than the beam direction of the left-hand polarization antenna. As the user switches from one polarization to the other polarization, the antenna rotates in azimuth direction in order to refocus the antenna toward the satellite, resulting in temporary disruption of signal reception. The antenna described above is designed for a fixed elevation beam angle.
U.S. Pat. No. 6,028,562 to Michael et al. describes a planar array of waveguide slot radiators of parallel waveguides which couples the electromagnetic signal from alternating +45 degree and −45 degree radiating slots interfaced on top of the waveguide to the slots on the broadwall of the waveguides via cavities which serve as impedance matching network. In a corresponding U.S. Pat. No. 6,127,985 to Michael et al., a similar slotted waveguide structure is employed. A T-shaped ridge waveguide is employed to realize closely spaced waveguide slot radiator to provide simultaneous dual polarization and suppression of grating lobes. The Michael patents have the disadvantage of complicated manufacturing processing. In addition, the patents use a rear-fed waveguide combining structure, which is not intended for electronic beam steering.
Conventional systems have focused the antenna beam toward the satellite while vehicle is moving using a mechanic dithering approach. In this approach, the antenna is rotated in both azimuth and elevation by a small angle, such as a fraction of the antenna beamwidth, to slightly off-point the antenna beam in the left, right, up, and down directions. The mechanic dithering involves controlling a motor to move the antenna platform. This approach has the shortcoming of a slow response and inaccuracies in the mechanic movement require the use of motion sensors (such as gyro, accelerometer, or compass) to aiding the tracking thereby resulting in significant signal degradation. Electronic dithering is faster, but still subject to the similar problems of slow response. The motion sensors are expensive.
Conventional techniques for attaching the antenna to a vehicle include embedding the antenna onto the roof or mounting the unit onto a luggage rack attached to the roof, see, for example, A5 antenna from KVH.
U.S. Pat. No. 6,653,981 describes an easy set up, low profile, vehicle mounted satellite antenna in which the antenna is mounted to a vehicle roof rack or a rail assembly motor vehicle. A retractable radome covers the antenna. The radome can be retracted when the antenna is not in use. Security locks are employed on the mounting brackets to protect the unit from unauthorized removal. It is desirable to provide an improved system for mounting a satellite to a vehicle.
SUMMARY OF THE INVENTION
The present invention relates to a vehicle mountable satellite antenna as defined in the claims which is operable while the vehicle is in motion. The satellite antenna of the present invention can be installed on top of (or embedded into) the roof of a vehicle. The antenna is capable of providing high gain and a narrow antenna beam for aiming at a satellite direction and enabling broadband communication to vehicle. The present invention provides a vehicle mounted satellite antenna which has low axial ratio, high efficiency and has low grating lobes gain. The vehicle mounted satellite antenna of the present invention provides two simultaneous polarization states.
In one embodiment, the present invention provides a ridged waveguide instead of a conventional rectangular waveguide to alleviate the effects of grating lobes. The ridge waveguide provides a ridged section longitudinally between walls forming the waveguide. A plurality of radiating elements are formed in a radiating surface of the ridged waveguide. The use of a ridged waveguide reduces the width of the waveguide, and thus, the spacing between the antenna slots. This suppresses the strength of the grating lobe. In conventional approaches, the length between cross slots along the waveguide is approximately one waveguide. The resultant beam points upward in the plane orthogonal to the waveguide axis. The present invention reduces the length between cross slots along the waveguide to further suppress the grating lobe. This results in further beam tilting away from the plane orthogonal to the waveguide axis. However, as long as the beam can be pointed to highest required elevation angle, the beam tilting does not have adverse effects on the overall system performance.
In an alternate embodiment, an inverted L-shaped waveguide has a first wall extending vertically downward from a top surface. The top surface can include a ridge portion. The top surface includes a plurality of radiating elements for forming a radiating surface.
In one embodiment, a hybrid mechanic and electronic steering approach provides a more reasonable cost and performance trade-off. The antenna aiming in the elevation direction is achieved via control of an electronic beamforming network. The antenna is mounted on a rotatable platform under mechanical steering and motion control for aiming the antenna in the azimuth direction. Such approach significantly reduces the complexity and increases the reliability of the mechanical design. The antenna height is compatible to the two-dimensional electronic steering phased-array antenna. Additionally, the number of the electronic processing elements required is considerably reduced from that of the conventional two-dimensional electronic steering phased-array antenna, thereby allowing for low cost and large volume commercial production.
The present invention provides electronically generated left, right, up, and down beams for focusing the antenna beam toward the satellite while the vehicle is moving. All of the beams are simultaneously available for use in the motion beam tracking. This provides much faster response and less signal degradation.
The waveguide couples the EM energy from all radiating elements in the waveguide axis direction and combines the energy together. It has been found that the loss through the waveguide coupling and combining is significantly lower than that using conventional approach utilizing passive microwave processing elements printed on the circuit board at the proposed operating frequency. In addition, the present invention also reduces the number of low noise amplifiers used in the antenna system because only one set of low noise amplifiers for each waveguide is used, as opposed to conventionally use of one set of low noise amplifier for each radiating element.
The ridged waveguide of the present invention produced a more concentrated field line near the center line of the broadwall, thereby reducing the width of the broadwall from a typical value for a conventional rectangular waveguide to about 0.398 inches at an example frequency in the direction of broadcast satellite range of about 12.2 GHz to about 12.7 GHz.
The vehicle mounted antenna system can include means for moveably mounting the satellite antenna adjacent to a moonroof and/or sunroof system. The satellite antenna is moveable to an open position beneath a transport plate of the moonroof and/or sunroof system and into a closed position beneath the vehicle roof.
The invention will be more fully described by reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an antenna system including a mobile platform in accordance with the teachings of the present invention.
FIG. 2A is a schematic diagram of an embodiment of a waveguide antenna of the present invention.
FIG. 2B is a schematic diagram of a waveguide body decomposition of the waveguide shown in FIG. 2A .
FIG. 2C is a schematic diagram of the waveguide shown in FIG. 2A .
FIG. 2D is an alternate embodiment of the waveguide shown in FIG. 2A .
FIG. 3 is a schematic diagram of an embodiment of a ridged waveguide.
FIG. 4A is a schematic diagram of an embodiment of a L-shaped waveguide.
FIG. 4B is a schematic diagram of a waveguide in decomposition of the waveguide shown in FIG. 4A .
FIG. 4C is schematic diagram of use of a dielectric material with a ridged waveguide.
FIG. 4D is a schematic diagram of use of a dielectric material with a L-shaped waveguide.
FIG. 4E is a schematic diagram of a waveguide antenna including the waveguide of FIG. 4A .
FIG. 4F is a schematic diagram of a waveguide antenna in decomposition including the waveguide of FIG. 4A .
FIG. 5A is a schematic diagram of an embodiment of a waveguide probe for use with the ridged waveguide.
FIG. 5B is a schematic diagram of an embodiment of a waveguide probe assembled for use with the ridged waveguide.
FIG. 6A is a schematic diagram of an embodiment of a waveguide probe for use with the inverted L-shaped waveguide.
FIG. 6B is a decomposition of the inverted L-shaped bend and probe.
FIG. 7 is a schematic diagram of an embodiment of a beam forming network.
FIG. 8 is a schematic diagram of an embodiment of an adaptive beam-tracking system.
FIG. 9A is a graph of an inferometer antenna pattern of the up and down beams at a center elevation angle at 65 degrees.
FIG. 9B is a graph of an inferometer antenna pattern of the up and down beams at a center elevation angle at 35 degrees.
FIG. 10 is a schematic diagram of an embodiment of an adaptive beam forming system.
FIG. 11 is a schematic diagram of a mounting system for a satellite antenna.
DETAILED DESCRIPTION
Reference will now be made in greater detail to a preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings and the description to refer to the same or like parts.
FIG. 1 is a schematic diagram of antenna system 10 in accordance with the teachings of the present invention. Waveguide antenna 12 comprises an antenna array formed of a plurality of waveguides 14 positioned parallel to each other on horizontal platform 13 . Horizontal platform 13 is rotatable under mechanical steering and motion control for aiming the antenna in the azimuth direction.
Waveguide axis 15 is in a direction perpendicular to the antenna aiming. Radiating surface 16 is the broad side facing the zenith direction. Radiating surface 16 of the waveguide antenna 12 includes a plurality of radiating elements 18 distributed at uniform spacing along waveguide axis 15 . Radiating element 18 provides coupling of electromagnetic (EM) energy between waveguide 14 and the free space. For example, radiating elements 18 can be X-shaped cross slots. Waveguide 14 couples the EM energy from all radiating elements 18 in the waveguide axis direction and combines the energy together.
In one embodiment, waveguide 14 is formed of a ridged waveguide, as shown in FIGS. 2A–D and 3 . Walls 19 have a narrow width W 1 . For example, walls 19 can have a width of about 0.08 to about 0.12 inches. Bottom 20 includes width W 2 typically wider than width W 1 . For example, width W 2 can be in the range of about 0.450 to about 0.470 inches. Bottom 20 is coupled to bottom portion 22 of walls 19 or bottom 20 can be integral with bottom portion 22 of walls 19 . Ridge section 21 is positioned longitudinally between walls 19 . For example, ridge section 21 can have a rectangular or square configuration. Ridge section 21 has a height H 1 which is smaller than height H 2 of walls 19 . For example, ridge section can have a height H 1 in the range of about 0.18 to about 0.33 inches and walls 19 can have a height H 2 in the range of about 0.2 to about 0.35 inches. Radiating surface 16 is coupled or integral with top portion 23 of walls 19 . Radiating surface 16 is in the range of about 0.02 inch to about 0.03 inches or about 0.03 inches thick.
Radiating elements 18 can be positioned along the direction of waveguide axis 15 with the phase centers of the cross slots of radiating elements 18 positioned along a straight line along waveguide axis 15 and in between a center line of waveguide ridge section 21 and one of walls 19 . In one embodiment, radiating elements 18 can be placed about half a waveguide wavelength apart. For example, the length of radiating elements 18 can be about 0.3 inches to about 0.5 wavelength or about 0.4 inches to about 0.5 inches at an operating frequency of a direct broadcast signal of about 12.2 GHz to about 12.7 GHz. Radiating elements 18 can be spaced, for example, about 0.5 inches to about 1.0 inches or about 0.9 inches apart. Radiating element 18 provides circular polarization at any transverse position. For example, the crossing angle of the two slots of the cross slot of radiating element 18 can be 60 degrees to about 90 degrees. Accordingly, the present invention allows broader freedom in cross slot design thereby providing a modified shape of a three dimensional pattern produced by the cross slot radiating element.
A typical requirement to operate such mobile antenna in the Continental United States (Conus), is that the antenna beam is steered from about 25 degrees to about 65 degrees in elevation. It has been found that in order to achieve high antenna gain and low axial ratio in such an operating range, the antenna gain is optimized toward about 40 degrees to about 45 degrees in elevation. This can be achieved by offsetting radiating element 18 from the center of waveguide axis 15 toward one of walls 19 . The gain and axial ratio is optimized by moving the cross slot of radiating element 18 toward wall 19 . The offset creates circular polarization and also tilts the antenna beam toward the lower elevation instead of the zenith direction. When the edge of the cross slots of radiating element 18 reaches wall 19 , the highest possible elevation with good axial ratio can be achieved is determined. This provides an elevation operating range of about 25 degrees to about 55 degrees.
In one embodiment, one or more waveguides 14 are formed from a metal, such as aluminum stock for forming walls 19 and bottom 20 including ridge portion 21 . Radiating surface 16 is also formed of a metal, such as aluminum stock. Radiating surface 16 is attached to waveguides 14 by a dip brazing process or using a series of mounting elements, such as screws, bolts, adhesives, and laser weldments, along walls 19 of waveguide 14 to provide proper electric conductivity along the joint between radiating surface 16 and waveguides 14 . It will be appreciated that alternative methods can be used for coupling radiating surface 16 to waveguides 14 , 40 .
An alternative construction is a metalized-surface plastic construction. Walls 19 and radiating surface 16 can be molded in a top piece of plastic having engaging hooks 24 along bottom portion 22 of walls 19 . Bottom 20 of waveguide 14 , including ridge section 21 , is molded as a second piece of plastic. Both the top and the bottom pieces are metalized, through a metal vapor deposit process or other processes known in the art. The top and bottom pieces can be snapped together through engaging hooks 24 , which also inserts pressure in the joint between radiating surface 16 and walls 19 of waveguides 14 , to ensure proper conductivity between the two pieces. This embodiment is suitable for low cost, mass production.
An antenna probe 25 is located on ends 27 , 28 of the waveguide 14 , as shown in FIG. 2 . Antenna probe 25 located on end 27 is used to couple a left-hand polarization signal from waveguide 14 to beam forming network 30 . Antenna probe 25 located on end 28 is used to couple a right-hand circular polarization signal from waveguide 14 to beam forming network 32 . Beam forming networks 30 , 32 provide low noise amplification of the signal and apply progressively phase shifts to the signals from different waveguides 14 to compensate for progressive signal propagation delays before the signals from different waveguides 14 are combined. By changing the amount of the progressive phase shift, the beam can be steered to different elevation directions.
FIGS. 4A–B and FIGS. 4D–E illustrate an alternative waveguide structure. Waveguide 40 comprises an inverted “L” shape. Wall 42 extends vertically downward from top surface 44 of waveguide 40 . For example, wall 42 can have a height H 3 in the range of about 0.3 to about 0.4 inches. The opposite wall 45 extends vertically downward from top surface 44 . For example, wall 45 can have a height H 4 in the range of about 0.05 to about 0.15 inches. The width of two walls 42 and 45 is in the range of about 0.04 to 0.12 inches. The width W 4 of the ridge portion 46 is in the range of about 0.06 to about 1.0 inches. Top surface 44 forms radiating surface 16 . A plurality of radiating elements 18 are formed in top surface 44 . Radiating elements 18 similar to those described above for waveguide 14 can be used in this embodiment. It will be appreciated that waveguide 40 can be used in all aspects of the present invention such as illustrated in the configuration of FIG. 1 , in place of waveguide 14 . The ridged waveguide in FIG. 3 is one embodiment of the inverted “L” shape in which H 3 is equal to H 4 .
The width W 3 of top surface 44 of the inverted “L” is small compared to the width of a conventional rectangular waveguide for the microwave frequency of interest to allow adjacent slotted waveguides to be close enough to eliminate grating lobes which would otherwise come into real space when the beam is scanned. For example, the width W 3 of top surface 44 can be in the range of about 0.4 to about 0.5 inches. Accordingly, waveguide 40 has a nominal internal width of about 0.32 to about 0.42 inches or about 0.35 to 0.40 freespace wavelengths facing the beam direction buried behind the face of waveguide 40 . Height H 3 , H 4 , and width W 3 , W 4 can be adjusted to slow the phase velocity in waveguide 40 . Accordingly, radiating elements 18 can be placed one waveguide wavelength apart and yet be close enough to each other to prevent grating lobes in the unscanned planes. Different variations of the L-shape waveguide 40 can be used to achieve the same radiation characteristics. Depth D 1 of ridge portion 46 can be adjusted to reduce the width W 3 .
Wall 42 as the vertical portion of the inverted “L” functions as a component of the waveguide width, thus enabling wave propagation similar to a conventional rectangular waveguide of a width approximately equal to the sum of wall 42 and top surface 44 of the “L”. The electromagnetic fields inside the “L” shaped waveguide 40 have a configuration which is similar to a simple dominant mode TE 1,0 rectangular waveguide. In FIG. 2 , the electric field is forced to be zero by wall 19 on the right side. The currents in that narrow wall are vertical and give rise to a magnetic field (H-field) parallel to the axis of the waveguide. At locations to the left of that narrow, the H-field gradually becomes transverse to waveguide axis. Crossed slots or radiating elements 18 located at the proper position are then excited by the same magnitude of H LONGITUDINAL and H TRANSVERSE and circular polarization is achieved because the two magnetic field components are in time quadrature.
The use of inverted L-shape waveguide 40 allows radiating elements 18 to be more freely positioned on radiating surface 16 of waveguide 40 such that a high elevation beam with good gain and axial ratio can be achieved. The radiating element 18 position can be adjusted by adjusting height H 3 , H 4 . In contrast, the achievable antenna property (gain and axial ratio) of the ridged waveguide at high elevation angle can not be moved beyond the edge of the waveguide wall 19 , limiting the achievable antenna property at high elevation angle.
In one embodiment, one or more waveguides 40 are formed from a metal, such as aluminum stock for forming walls 42 and walls 45 . Radiating surface 16 including top surface 44 is also formed of a metal, such as aluminum stock. Radiating surface 16 is attached to wall 42 and wall 45 by a dip brazing process or using a series of mounting elements, such as screws, bolts, adhesives and (laser) weldments, along radiating surface 16 of waveguide 40 to provide proper electric conductivity along the joint between radiating surface 16 and waveguides 40 . It will be appreciated that alternative methods can be used for coupling radiating surface 16 to waveguides 40 .
An alternative construction is a metalized-surface plastic construction. Walls 42 can be molded in a top piece of plastic having engaging hooks 46 along top portion 48 of walls 42 . Radiating surface 16 , including ridge section 45 , is molded as a second piece of plastic. Both the top and the bottom pieces are metalized, through a metal vapor deposit process or other processes known in the art. The top and bottom pieces can be snapped together through engaging hooks 46 , which also inserts pressure in the joint between radiating surface 16 and wall 42 of waveguides 40 , to ensure proper conductivity between the two pieces. This embodiment is suitable for low cost, mass production.
Another approach to achieve high gain, low grating lobe, and good axial ratio is to employ low loss dielectric-loaded waveguide as shown in FIG. 4C and FIG. 4D . The dielectric-loaded waveguide employs a low loss dielectric material to fill in the entire interior 52 of the waveguides 14 , as shown in FIG. 4C . A dielectric material can be used to fill interior 53 of waveguide 40 , as shown in FIG. 4D . All waveguide walls and radiating surface are formed by metal coating the dielectric material 14 . The cross-slot radiating elements 18 on the top radiating surface should be left uncoated such that the dielectric material is exposed to air in that portion. The gap between two adjacent waveguide should also be filled with metal or other conducting material. The wavelength within the dielectric material is inversely proportional to the square of the dielectric constant of the dielectric material. The use of dielectric material allows the wavelength within the waveguide to be significantly reduced, thereby suppressing the grating lobes and increasing the antenna gain. A suitable dietectric material 50 is C-Stock from Cuming Microwave and Eccostock HT003 from Emerson Cuming.
Referring to FIGS. 5A–B , an embodiment of antenna probe 25 is shown. Antenna probe 25 is used for coupling electromagnetic energy between waveguide 14 and an active beam forming circuit board. Waveguide 14 includes waveguide bend 62 to rotate the feed end of waveguide 14 downward. For example, waveguide bend 62 can be about 90 degrees. Waveguide bend 62 also reverses the orientation of ridge section 21 within waveguide 14 . Antenna probe 25 is printed onto surface 63 of beam forming network printed circuit board 64 . For example, beam forming network printed circuit board 64 can be a two layered printed circuit board (PCB). Antenna probe 25 is formed as an extension of the microstrip 65 . Antenna probe 25 can have a termination 66 having a larger dimension than microstrip 65 . For example, termination 66 can be rectangular. Termination 66 is attached by microstrip 65 to ridge section 21 at lower end 67 of waveguide bend 62 . Cavity 68 under antenna probe 25 terminates waveguide bend 62 . For example, cavity 68 can have a depth of about a quarter wavelength. Through holes 69 connect to microstrip 65 .
Corresponding to the position of waveguide wall 19 , a grounded strip, such as formed of copper, containing a series of ground vias (not shown) forms the continuation of the waveguide wall 19 . An active low noise amplifier can follow antenna probe 25 on microwave beam forming network printed circuit board 64 to amplify the signal. The probe shown in FIG. 5 has been analyzed using the Ansoft's EM simulation CAD tool called High Frequency Structure Simulator HFSS. It was demonstrated that less than about 0.2 dB loss can be achieved using this probe implementation. Antenna probe 25 has low loss and is easy to manufacture. The employment of the 90 degree bend allows the antenna probe is be realized as part of the PCB. Accordingly, no additional attachment mechanism is required. This is advantageous to the ease of manufacturing and reliable performance.
FIGS. 6A–B illustrate an embodiment of an antenna probe which can be used with the inverted L-shaped waveguide. Waveguide 40 includes waveguide bend 72 to bring top surface 44 and ridged portion 48 of waveguide 40 downward and to a microstrip line transition. Waveguide bend 72 also converts the inverted L-shaped ridge waveguide to a symmetric ridge waveguide. For example, bend 72 can be about 90 degrees. Antenna probe 25 comprises microstrip portion 74 printed onto one side of a microwave beam forming network printed circuit board 64 . Waveguide 40 is press fit onto the microstrip portion 74 through a section of conducting block 75 and termination 76 to form the waveguide to microstrip line transition. For example, termination 76 can be rectangular or square 42 . Wall 19 is connected to the ground plane of the microstrip portion 74 through via holes 77 show in FIG. 6 . The ground plane at the bottom of the PCB 64 terminates the waveguide. The probe implementation shown in FIG. 6 has been analyzed by using the Ansoft's EM simulation CAD tool called High Frequency Structure Simulator HFSS. It was demonstrated that less than about 0.2 dB loss can be achieved using this probe implementation. This antenna probe waveguide termination design offers the same advantages of ease of manufacturing, low loss, and reliable performance as that in FIG. 5 .
An embodiment antenna beam forming networks 30 , 32 is shown in FIG. 7 . Beam forming networks 30 , 32 comprises antenna probe 25 , low noise amplifier 80 , bandpass filters 81 , 82 , downconverter 88 , phase shift elements 86 , 87 , and combiners 84 . Low noise amplifier 80 amplifies the received signal and bandpass filters 81 , 82 remove the adjacent band interference and noise for each waveguide 14 , 40 which is passed to LPF 83 . Combining network 84 combines the signal from all waveguides 14 , 40 after the phase of the received signals from each waveguide 14 is adjusted by phase shift elements such that the signals are combined in phase. Series delay lines 86 feed local oscillator (LO) signal 87 into downconverters 88 . Series delay lines 86 can be used to generate a progressive phase shift in the local oscillator signal used in the downconverter 88 for each waveguide signal such that the signals at the output of the downconverters 88 are in phase, as described in U.S. patent application Ser. No. 10/287,370 and application Ser. No. 10/287,371, hereby incorporated in their entirety by reference into this application. Accordingly, combiners 84 add up all the signals in phase. This is the received signal which is passed to the receiver demodulator. By changing the LO frequency, different amounts of progressive phase shifts are generated, allowing the beam forming networks 30 , 32 to steer the antenna beam to different elevation directions. Once the beam is formed, the signal is passed to frequency translator 89 to convert the signal to the desired output frequency.
To facilitate the in-motion pointing of the antenna beam toward a satellite, the present invention provides four additional antenna beams, such as left/right and up/down beams. Left beam 91 and right beam 92 are created by using different cross slot spacing along even and odd numbers of waveguides 14 , shown in FIG. 1 . Wider spacing allows one beam to tilt less than the other beam using the narrower slot spacing or pitch, as shown in FIG. 1 . Combining an odd waveguide 14 in adaptive beam forming module 90 a creates left beam 91 and combining an even waveguide 14 in module 90 b creates right beam 92 or vise versa depending on if a wider or narrower slot spacing is used on an odd or even waveguide, as shown in FIG. 7 .
Referring to FIG. 7 , the phase center of the beam created by the first half of waveguides 14 is at a significantly larger distance (multiple waveguide width) from the phase center of the beam created by the second half group of waveguides 14 . The distance between the phase centers allow the interferometer antenna pattern as shown in FIGS. 9A–9B to be created. As shown in FIG. 7 , the combining network provides two outputs which sums up the signals from first half (1, 2, . . . 16) of the waveguides and those from the second half (17, 18, . . . 32) of the waveguides. Up beam 93 is formed by combining a 90 degree phase shifted of the first half of waveguides 14 and a second half of waveguides 14 . Down beam 94 is formed by the combining the first half of waveguides 14 and the 90 degree phase shifted of the second half of waveguides 14 .
In FIG. 9A , the up beam pattern and the SUM beam pattern are shown. The SUM beam pattern points to a 65 degree elevation angle in FIG. 9A and the up beam points to slightly higher elevation angle by approximately 2 degrees. In FIG. 9B , the SUM beam points to a 30 degree elevation angle and the up beam points to approximately 33 degrees. Similar pattern for down beam can be generated with down beam points approximately 2 to 3 degrees below the SUM beam. In the preferred embodiment, the 90 degree phase shifter is used to generate the up and down beam for ease of implementation. Alternatively, phase shifters with other angles can be used to create similar up and down beams with greater or smaller angle separation from the SUM beam.
Sum beam 98 , left beam 91 , right beam 92 , up beam 94 , and down beam 95 in mux 97 , are shown in FIG. 7 . Satellite in-motion tracking can be accomplished by monitoring the signal powers of left beam 91 , right beam 92 , up beam 93 , and down beam 94 with power detector 99 . Left beam 91 and right beam 92 are compared against each other and sum beam 98 to obtain information regarding the antenna pointing error in the azimuth direction. Up beam 93 and down beam 94 are compared against each other and sum beam 98 to obtain information regarding the antenna pointing error in the elevation direction. The azimuth error is used to adjust the azimuth motor to dynamically move antenna platform 13 , as shown in FIG. 1 , and the elevation error is used to adjust the electronic beam steering networks 30 , 32 to move the beam in the elevation direction to focus the beam to the satellite during in-motion tracking of the satellite. Accordingly, the present implementation of the left/right/up/down beams allows the antenna to track the satellite during vehicle motion. The use of the four antenna beams allows the in-motion tracking to respond significantly faster than conventional systems. The antenna in-motion tracking can therefore be accomplished without or with a minimum number of motion sensors, thereby, reducing the overall cost of the system.
In another embodiment, in-motion antenna tracking can be used in antenna system 10 . An adaptive beam forming processing as shown in FIG. 8 is employed in the in-motion antenna tracking system to automatically track the beam in elevation direction through the beam forming network. The adaptive beam forming processing is based on the principle of a correlating signal to derive a set of antenna weights to optimize the combined signal-to-noise ratio. By applying such operation to the output signal of each waveguide 14 , a set of antenna weights can be generated to automatically optimize the output signal-to-noise ratio. This is equivalent to precisely pointing the antenna beam to the satellite direction. The (pre-detection) signal-to-noise ratio of the output of individual waveguide is typically quite low (close to 0 dB) to typical satellite signal applications. For example, the correlation is done by multiplying two signals and then integrating (or equivalently, low pass filtering of) the output of the multiplier. The time of integration (or the bandwidth of the integration) determines the post-detection signal-to-noise ratio. Integration time of 100 uS to 1 mS can bring the post-detection signal-to-noise ratio to more than 10 dB, thereby enabling accurately determination of the antenna weight used for combining. The adaptive beam forming processing can be based on the principle of Maximum Ratio Combining (MRC), Constant Modulus Algorithm (CMA), Multiple Signal Classifications (MUSIC), or various other principles to maximize the signal-to-noise ratio. Adaptive signal processing is applied to the elevation angle tracking for antenna system 10 . In a two dimensional phased-array antenna, the adaptive signal processing technique can be applied to track the signal in both elevation and azimuth direction.
An embodiment of the adaptive beam tracking system 100 based on MRC is illustrated in FIG. 10 . The signals from a plurality of waveguides 14 , 40 are input into the beam forming processing. It will be appreciated that various numbers of antennas and processing elements could be used in accordance with the teachings of the present invention. Modulators 102 a–d apply determined antenna weights 103 to the signal. Modulators 102 a–d are controlled by the antenna weight to generate the desired phase shift and gain scaling for the signals. The outputs of modulators 102 a–d are combined in summer 104 to generate combined (beam formed) output signal 106 .
The antenna weight is computed by downconverting the input signals and the combined signal to baseband. In one embodiment, a direct down-conversion processing is employed in which the LO frequency is the same as the input signal frequency. The signal is thereby converted to the baseband. The output of the downconverter is first filtered to extract the signal in the desired frequency band. The signals from plurality of waveguides 14 , 40 are downconverted in respective downconverters 110 a–d . Each of downconverters 110 a–d multiplies the signal from a different waveguide 14 by a local oscillator in-phase signal (LOI) and a local oscillator quadrature phase signal (LOQ). The resultant signals are applied to respective low-pass filters (LPF) 112 a , 112 b in a baseband automatic gain control (AGC) loop 116 that normalizes the signal level before the MRC algorithm. AGC loop 116 provides a consistent performance at different input signal levels. Variable gain amplifiers 118 a , 118 b are applied to the respective outputs of LPF 112 a , 112 b and MRC beamforming module 120 . At the output of the variable gain amplifiers 118 a , 118 b , power detectors 117 are applied to sum the signal power of all antennas and compare the signal power to a threshold value. The difference between the signal power of all antennas and the threshold value can be integrated to maintain the signal level after AGC loop 116 at the same level and can be used to adjust the gain of variable gain amplifiers 118 a , 118 b . Accordingly, in this implementation, the MRC algorithm is able to work at different input signal levels.
MRC beamforming module 120 performs real time adaptive signal processing to obtain the maximum signal-to-noise ratio. In an implementation of MRC beamforming module 120 the antenna weights are used to align the phases of the four antenna signals received from waveguides 14 and also scale the signal in proportion to the square-root of the signal-to-noise ratio in each individual channel. In one implementation, the signal envelope is used as an approximation to scale the signal in proportion to the square-root of the signal-to-noise ratio in each individual channel.
MRC beamforming module 120 can employ a Cartesian feedback loop. MRC beamforming module 120 provides baseband processing which performs complex conjugate multiplication of the output of a baseband I and Q channel filter with a baseband reference I and Q channel as follows:
I _ERROR i =I i *I s +Q i *Q s
Q _ERROR i =I i *Q s −Q i *I s
The resultant signal (I_ERROR i , Q 13 ERROR i ) at the output of MRC beamforming module 120 is a complex signal with phase equal to the difference of the reference complex signal and the individual signal and an envelope proportional to the envelope of the individual signal. Signal I_ERROR is applied to integrator 122 a and signal Q_ERROR is applied to integrator 122 b . The output of the LPFs 122 a , 122 b is antenna weight 103 (IWi, QWi, i=1,2,3, . . . ). The antenna weight normalization computes the summation of all the antenna weight and normalizes the summation to a constant through the use of the feedback operation.
Combined signal 106 is applied to downconverter 128 and is multiplied by LOI and LOQ. The resultant signals are applied to low-pass filters (LPF) 130 a , 130 b . The outputs from the low-pass filters (LPF) 130 a , 130 b are amplified with quadrature phase signal amplifiers 131 a , 131 b and applied to antenna weight magnitude normalization module 132 .
Antenna weight magnitude control loop 132 monitors the power in the combined signal. If the magnitude of the weight is small, the power of the combined signal is small. Alternatively, if the magnitude of the weight is large, the power of the combined signal is large. A power detector can be used in the antenna weight magnitude control loop 132 to compare the power of combined signal 106 with a threshold level. The difference between the power of combined signal 106 and the threshold level is filtered such as with a low-pass filter (LPF). The filtered output can be fed forward to the variable gain amplifiers to adjust the magnitude of the combined signal. A higher gain in the variable gain amplifiers produces a larger antenna weight and a lower gain in the variable amplifiers produces a smaller antenna weight. By varying the gain of the variable gain amplifiers in the baseband SUM channel signal paths, the magnitude of the antenna weight is adjusted to a proper level to keep the output signal power in a small range.
Output from antenna weight magnitude normalizing module 132 is amplified with quadrature phase signal amplifiers 134 a , 134 b and is applied to MRC beamforming module 120 to be used for updating antenna weight 103 , as described above.
An advantage of the adaptive beam forming processing of the present invention is a fast response and reliable tracking in the elevation beam. This is achieved via the processing on the phase of the signal directly instead of processing on the signal power as in the conventional elevation tracking system. Generally, the adaptive processing of the present invention achieves fast and reliable performance in a much lower signal-to-noise ratio. Additionally, the adaptive processing as illustrated in FIG. 10 is amendable to integrated circuit processing, thereby, reducing the overall cost of the system. Another advantage of present invention is that the overall tracking can be greatly simplified because the system now only needs to monitor the power of left and right beam and command the motor to move the antenna to track in azimuth direction. Accordingly, no motion sensors are used.
FIG. 11 illustrates a system for mounting a satellite antenna 200 in accordance with the teachings of the present invention. Satellite antenna 202 is movably mounted adjacent to moonroof/sunroof system 204 . Moonroof/sunroof system 204 can be a conventional system for vehicles in which moonroof/sunroof system 204 includes plate 206 which fits within hole 207 formed in roof 208 of a vehicle to allow sun and moonshine into the passenger compartment. Moonroof/sunroof system 204 can comprise a moonroof or a sunroof or both a moonroof and a sunroof. For example, plate 206 can be formed of glass or a transparent material, such as Levan. Alternatively, plate 206 can be formed of similar components as the vehicle exterior. Sliding shade 209 can be slidably mounted to the vehicle beneath moonroof/sunroof system 204 . Sliding shade 209 is used to block outside light if no sun or moonshine is desired, sliding shade 209 slides to cover plate 206 to block outside light. Moonroof/sunroof system 204 and sunshade 209 slide mechanically to completely or partially fill hole 207 in roof 208 . Moonroof/sunroof system 204 can slide either automatically or manually. When hole 207 in roof 208 is completely opened to the outside, moonroof/sunroof system 204 and sunshade 209 care moved behind hole 207 into opening 210 positioned between roof 208 and roof liner 212 . When hole 207 in roof 208 is complete closed to the outside, moonroof/sunroof system 204 and sunshade 209 are moved from opening 210 to fill hole 207 in roof 208 .
Satellite antenna 202 can separately slide under plate 206 of moonroof/sunroof system 204 . During use of satellite antenna 202 , plate 206 is moved to close hole 207 to the outside and satellite antenna 202 is moved from opening 214 between vehicle roof 208 and roof liner 212 to beneath plate 206 . In one embodiment, plate 206 formed of a glass or transparent material functions as a radome. When satellite antenna 202 is not in use, satellite antenna 202 is moved within opening 214 . It will be appreciated that tracks can be formed within opening 210 or opening 214 for receiving respective plate 206 or satellite antenna 202 and opening 210 and opening 214 can be combined as a single opening. Movement of plate 206 and satellite antenna 202 can be accomplished by drive means 215 . For example, drive means 215 can be one or more motors or hydraulic pumps or other conventional means known in the art to provide sliding movement.
Satellite antenna 202 can have a low profile and dimensions to allow satellite antenna 202 to be implemented with a conventional moonroof/sunroof system. Satellite antenna 202 can have a diameter of less than or equal to width of plate 206 . For example, satellite antenna 202 can have a diameter of less than about 24 inches. Satellite antenna 202 can be antenna system 10 with waveguide 12 or waveguide 40 or can be an antenna described in U.S. Pat. No. 6,653,981, hereby incorporated by reference into this application. It will be appreciated that other types of antenna satellites can be used for movement adjacent the moonroof/sunroof system in accordance with the teachings of the present invention.
It is to be understood that the above-described embodiments are illustrative of only a few of the many possible specific embodiments, which can represent applications of the principles of the invention. Numerous and varied other arrangements can be readily devised in accordance with these principles by those skilled in the art without departing from the spirit and scope of the invention. | The present invention relates to a vehicle mountable satellite antenna as defined in the claims which is operable while the vehicle is in motion. The satellite antenna of the present invention can be installed on top of (or embedded into) the roof of a vehicle. The antenna is capable of providing high gain and a narrow antenna beam for aiming at a satellite direction and enabling broadband communication to vehicle. The present invention provides a vehicle mounted satellite antenna which has low axial ratio, high efficiency and has low grating lobes gain. The vehicle mounted satellite antenna of the present invention provides two simultaneous polarization states. | 7 |
This application is a continuation of Ser. No. 07/026051 filed 3-16-87, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to heat sealable semicrystalline polymeric materials and particularly to heat sealable semicrystalline polymeric materials having a quasi-amorphous surface layer of the same or similar polymeric material.
2. Background of the Art
The effects of actinic radiation on the degradation of polymer surfaces have been studied for many years. Prior to about 1970, this work was done with low intensity photolamps at wavelengths greater than 220 nanometers (nm). Numerous papers are available in the literature, typical of which are Day and Wiles, Journal of Applied Polymer Science, 16 175 (1972), and Blais, Day and Wiles, Journal of Applied Polymer Science, 17 p. 1895 (1973).
Between 1970 and 1980 the effects on polymer surfaces of ultra-violet (UV) lamps with wavelengths less than 220 nm were studied for lithography and surface modification purposes. Such studies are exemplified by Mimura et al., Japanese Journal of Applied Physics, 17 541 (1978). This work illustrates that long exposure times and high energies are required to cause photo-etching when UV lamps are used. U.S. Pat. No. 3,978,341 (Hoell) teaches an apparatus for exposing polymeric contact lenses to a spark discharge producing 83 nm to 133.5 nm U.V. radiation to improve the wettability and adhesiveness of the lenses.
In 1975 the excimer laser was discovered. An excimer laser is an excited dimer laser where two normally non-reactive gases (for example Krypton, Kr, and Fluorine, F 2 ) are exposed to an electrical discharge. One of the gases (Kr) is energized into an excited state (Kr*) in which it can combine with the other gas (F 2 ) to form an excited compound (KrF*). This compound gives off a photon and drops to an unexcited state which, being unstable, immediately disassociates to the orginal gases (Kr and F 2 ) and the process is repeated. The released photon is the laser output. The uniqueness of the excimer laser is its high efficiency in producing short wavelength (UV) light and its short pulse widths. These attributes make the excimer laser useful for industrial applications. Kawamura et al., Applied Physics Letters, 40 374 (1982) reported the use of a KrF excimer laser at 248 nm wavelengths to photo-etch polymethyl methacrylate (PMMA), a polymer used in preparing photolithography resists for semiconductor fabrication.
U.S. Pat. No. 4,414,059 (Blum, Brown and Srinivasan) disclosed a technique for the manufacture of microelectronic devices utilizing ablative photodecomposition of lithography resist amorphous polymers at wavelengths less than 220 nm and power densities sufficient to cause polymer chain fragmentation and immediate escape of the fragmented portions. The photodecomposition leaves an etched surface. The authors found that using an ArF excimer laser at 193 nm and with a 12 nanosecond pulse width, a threshold for ablatively photo decomposing poly(methylmethacrylate) resist material occurs at about a fluence of 10-12 mJ/cm 2 /pulse. It is stated that large amounts of energy, greater than the threshold amount, must be applied before ablation will occur. The energy used must be 1) sufficiently great and 2) applied in a very short amount of time to produce ablative photodecomposition.
U.S. Pat. No 4,417,948 (Mayne-Banton and Srinivasan) and a related publication, Srinivasan and Leigh, Journal American Chemical Society, 104 6784 (1982) teach a method of UV photo etching poly(ethylene terephthalate) (PET). In these publications the authors indicate the mechanism of photo etching to be one of chain scission or bond breaking of surface polymer molecules by the high energy UV. Bond breaking continues in the presence of irradiation and the smaller units continue to absorb radiation and break into still smaller units until the end products vaporize and carry away any excess photon energy. This process results in small particles being ablated away, and various gases being evolved. The remaining surface material comprises molecules of low molecular weight (oligomers). Examining the PET repeating unit and the author's claim of bond scission, it is believed that the following occurs: ##STR1## Indeed, in the Journal of the American Chemical Society article, the authors analyze for benzene and start detecting it at about the threshold for photodecomposition for PET; i.e., about 20 mJ/cm 2 /pulse at 193 nm. The authors also indicate that the photo etch process is accelerated in the presence of oxygen which seals the ends of the broken chain's fragments and prevents recombination of these fragments.
Srinivasan, Journal of the Vacuum Society, B1, 923 (1983) reports the results of ablative photodecomposition of organic polymers through a 0.048 cm diameter mask and states that a threshold exists for the onset of ablation and, for PMMA, that the threshold is 10 mJ/cm 2 /pulse. He then goes on to state that one pulse at 16 mJ/cm 2 gave an etch mark on PMMA while 50 pulses at 4 mJ/cm 2 /pulse left no detectable etch marks. For PET and polyimide, the threshold began at about 30 mJ/cm 2 /pulse. However, for a satisfactory etch pattern the optimum fluence ranged from 100 to 350 mJ/cm 2 /pulse.
In Srinivasan and Lazare, Polymer, 26, 1297 (1985) Conference Issue, the authors report the photo etching of 6 X 12 mm samples of PET, PMMA and polyimide polymers with both continuous radiation at 185 nm from UV lamps and pulsed radiation at 193 nm from an excimer laser. The use of continuous low energy UV lamps causes photo oxidation of the polymer surface with a resultant increased oxygen to carbon ratio (O/C ratio) as determined by x-ray photoelectron spectroscopy (XPS) equipment, while the use of a pulsed high energy excimer laser, which produces chain scission in and ablation of the polymer surface, resulted in a lower O/C ratio as determined by XPS. The authors then go on to say "It may be pointed out that ablative photo decomposition is not exactly a method for the modification of a polymer surface at an atomic level since it totally eliminates the atoms at the surface and creates a fresh surface."
U.S. Pat. No. 3,607,354 discloses the use of highly active hydroxybenzene solvents to delustre the surface of an oriented poly(ethylene terephthalate) film. The solvent acts to dissolve and swell the PET and remains in the surface layer. The chemical composition of the surface layer is different from that of the bulk polymer because of the presence of the very active solvents and the formation of large spherulitic crystals which interrupt the transmission of light through that layer is believed to occur.
U.S. Pat. No. 4,568,632 (Blum, Holloway and Srinivasan) claims a method for photo etching polyimides. The process described uses a pulsed excimer laser at 193 nm. The stated incident energy required for photo ablation is much higher for polyimide than for PET. The values for the laser fluence threshold of PET was reported as about 30 mJ/cm 2 /pulse while for polyimide it was reported as about 50 mJ/cm 2 /pulse. An operative level was noted as about 50-100 mJ/cm 2 /pulse for PET and 100-300 mJ/cm 2 /pulse for polyimide. The etch rate found for PET was 1000 Angstroms for a fluence of 100-300 mJ/cm 2 /pulse and for the polyimide was 750 Angstroms for 350 mJ/cm 2 /pulse.
Lazare and Srinivasan, Journal Physical Chemistry, 90, 2124 (1986) report on the study of surface properties of PET which have been modified by either pulsed UV laser radiation or continuous UV lamp radiation. The authors report on the high fluence ablation of PET as follows: 1) the PET irradiated surface is a layer of low molecular weight material, 2) the surface has a rough chemically homogeneous texture, 3) the surface has a high chemical reactivity characteristic of oligomers, and 4) the surface could be removed by washing in acetone. Since extremely low molecular weight fragments (oligomers) of PET are soluble in acetone, the authors assert this removal of the treated surface is indicative of the presence of low molecular weight material on the surface. The authors also report that the low intensity UV lamp treated PET surfaces would not wash off with acetone. This later article reports thresholds for ablation of PET at about 30-40 mJ/cm 2 /pulse.
Japanese Patent Publications JA 59-82380, JA 59-101937 and JA 59-101938 (Kitamura, Veno and Nomura) describe the treatment of various polymers with many pulses from moderately high energy lasers for the purpose of increasing adhesion and forming a barrier layer to prevent plasticizer migration from within certain polymers.
Bishop and Dyer, Applied Physics Letters, 47, 1229 (1985) extended the photoablation etching work of others to actually cutting through or slitting the polymer film by increasing the energy density of the laser beam by concentrating it at the film surface.
The authors of the above references were studying the photodecomposition or photoablation process of UV radiation on polymer surfaces, without regard to whether the polymer was semi-crystalline or amorphous. The present invention does not produce substantial photodecomposition and little or no photoablation, and is concerned only with semicrystalline polymer surfaces produced by exposure to an energy regime different from those used in the prior art.
"Polymer Interface and Adhesion", Souheng Wu, Published by Marcel Dekker, Inc., N.Y. and Basel, Chapter 5, page 206 indicates that when a polymer melt cools and solidifies, an amorphous surface is usually formed, although its bulk phase may be semicrystalline. This is at least in part a result of the presence of fractions or materials which are not readily accomodated in the crystalline structure being rejected to the surface. This amorphous surface is believed to be extremely thin, corresponding to only a few layers of molecules, and is of the order of no more than 2 or 3 nm, and is generally less than 2 nm in thickness.
U.K. Patent No. 1,579,002 discloses vacuum glow discharge treatment of polymeric surfaces to increase adhesion to that surface. The glow discharge (i.e., corona type discharge) in the vacuum reduces the yellowing typically resulting from corona discharge treatment by 75 to 80%. The surfaces are heated to a temperature below the glass transition temperature or melting point during glow discharge treatment.
U.S. Pat. No. 3,081,485 describes a process for heating and softening polymeric materials using electron-beam irradiation so that further mechanical treatment such as stretching and coating can be carried out. The energy densities used (e.g., column 2, line 15) are about two orders of magnitude higher than the energy densities used in the present invention. The energy levels described in U.S. Pat. No. 3,081,485 would cause ablation. The authors note on column 2, lines 26 ff. that small traces of irradiated material are evaporated during irradiation. Although the patent describes surface heating, the immediate depth of e-beam penetration (see column 3) appears to be greater than 150 microns. This form of energy would have equal effects on the bulk polymer and would not cause only surface modifications.
U.S. Pat. No. 4,631,155 describes the surface modification of polymers by subjecting the surface to at least one pulse of intense electromagnetic radiation. The surface polymer is disoriented during the relatively long exposure to radiation. Disorientation is indicative of any amorphous surface. Very thick amorphous layers appear to be formed as indicated by the chloroform test described in column 5, and it is very likely that treatment under the conditions described in this patent would cause surface chemical changes.
SUMMARY OF THE INVENTION
The present invention provides a process for heat sealing at least one amorphized surface layer on semicrystalline polymers to another surface. Some of the special properties in the preferred semicrystalline polymers used in this invention are reduced optical reflectance and increased optical transmission, increased coating adhesion, increased auto-adhesion, and a non-yellowed (non-degraded) surface. The preferred polymeric article used in the present invention comprises a semicrystalline polymer having on at least one surface thereof areas having a depth of at least 5 nm of the same polymer composition in a quasi-amorphous state. The areas may be continuous or discontinuous.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE shows a chart which indicates the relationship of bond strengths to the number of pulses/fluence of modifying radiation.
DETAILED DESCRIPTION OF THE DRAWING
The FIGURE graphically shows the effects of surface modification according to procedures for forming the article used in the practice of the present invention and shows effects of other known processes on properties on poly(ethylene terephthalate) film.
The diagonal line represents constant energy density. That is, the number of pulses multiplied by the energy per pulse remains constant along that line. The shaded area (1) shows microtexturing of the surface which occurs with ablation and etching techniques. This tends to produce high bond strengths. The crosshatched area (2) shows surface modification according to the present invention wherein the properties of the surface can be controlled between strong (greater than 2000 g/linear inch), medium (1000-2000 g/linear inch) and weak (0-1000 g/linear inch) bonds. These bond strengths are for autoadhesion of the surfaces.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a process for heat sealing at least one film having at least one amorphized surface layer on a semicrystalline polymer. This surface is preferably formed by the irradiation of the polymer by radiation which is strongly absorbed by the polymer and of sufficient intensity and fluence to cause such amorphized layer. The semicrystalline polymer surface is thus altered into a new morphological state by radiation such as an intense short pulse UV excimer laser or short pulse duration, high intensity UV flashlamp.
The quasi-amorphous surface layer or areas produced according to the practice of the present invention are generally and preferably substantially, essentially, or even totally free of polymeric decomposition debris which typically results from ablative processes as described in U.S. Pat. No. 4,417,948 and the articles of Srinivasan et al. noted above.
The residual debris denoted above would be organic material having a lower oxygen/carbon ratio than the bulk polymer. Even if not visually observable in the amounts present, the debris itself would be yellower in color than the bulk material and would be more highly conjugated. The debris also tends to leave microscopically observable (at least 10,000, preferably 20,000X) artifacts on the surface recognizable as debris and not merely texturing. With respect to poly(ethylene terephthalate), ablation produces a surface substantially soluble in acetone, while the preferred quasi-amorphous surface is not in acetone.
The process of the present invention comprises 1) placing two surfaces in contact with one another, one of the surfaces comprising a semicrystalline polymer, the contacting surface of which has areas of the same polymer in a quasi-amorphous state, the areas having a depth of at least 5 nm, and 2) heating the areas of contact between said two surfaces sufficiently to cause bonding therebetween. The temperature used is, of course, dependent upon the polymers used, each polymer having different softening, melting, or fusing temperatures The temperature may be as low as 100° C. although minimum temperatures of 110° C. or 120° C. are more common. The limit on temperatures at the interface should be lower than those that would degrade the polymer (generally lower than 400° C.) or disrupt the semicrystalline structure or orientation (generally lower than 300° C.).
Pressure is of course desirable during the process to keep the surfaces intimately engaged during heat sealing. This may be accomplished by platens or rollers or the like. Pressure on the order of at least 5 g/cm 2 is desirable with pressures of at least 10 g/cm 2 or 50 g/cm 2 being more preferred.
In understanding the present invention, a number of terms and concepts should be appreciated. The treatment of the surface of semicrystalline polymeric materials according to the present invention does not add or substantially remove material from the surface. Residual solvent or residual low molecular weight reactants and additives may be volatilized during this treatment, but there is less than 0.1% or 1% degradation (to a volatile state) and/or volatilization of the bulk of polymeric material (within the amorphized layer or melted volume) having a molecular weight in excess of 10,000. The chemical modification of the polymer surface (e.g., oxidation, chain breakage) is minimal if there is any at all. Only a small amount of chain breakage occurs, without the generation of significant amounts (i e , greater than 1% or 0.1% by bulk weight) of materials volatilized during the process.
The terms amorphous, crystalline, semicrystalline, and orientation are commonly used in the description of polymeric materials. The true amorphous state is considered to be a randomly tangled mass of polymer chains. The X-ray diffraction pattern of an amorphous polymer is a diffuse halo indicative of no regularity of the polymer structure. Amorphous polymers show softening behavior at the glass transition temperature, but no true melt or first order transition.
The semicrystalline state of polymers is one in which long segments of the polymer chains appear in both amorphous and crystalline states or phases. THe crystalline phase comprises multiple lattices in which the polymer chain assumes a chain-folded conformation in which there is a highly ordered registry in adjacent folds of the various chemical moieties of which the chain is constructed. The packing arrangement (short order orientation) within the lattice is highly regular in both its chemical and geometric aspects. Semicrystalline polymers show characteristic melting points, above which the crystalline lattices become disordered and rapidly lose their identity. The X-ray diffraction pattern of semicrystalline polymers (or copolymers) generally is distinguished by either concentric rings or a symmetrical array of spots, which are indicative of the nature of the crystalline order.
Orientation of the polymer is the directional alignment of the polymer chain (long-range order) or segments of the polymer (chain) within the polymer composition. In the quasi-amorphous state described in the practice of the present invention, it appears that the overall long-range order orientation or ordering of the crystal lattice remains in an apparent crystalline orientation. It also appears that there is, however, significant localized disordering along the chain (short-range order orientation). The quasi-amorphous form thus exhibits short-range order non-orientation or low orientation typical of amorphous phases while it exhibits long-range ordering typical of crystalline structures. These characteristics are observable and determinable by single analytic techniques or combinations of techniques such as X-ray diffractions, spectromicrophotometry, IRRAS, NMR, solvent extraction, and the like.
The surface of the semicrystalline polymer is converted into its quasi-amorphous form by heating and rapid cooling of a determined amount of that surface. A determinable depth of the polymer composition is converted to the quasi-amorphous state. The conversion is referred to as "amorphizing." The thickness of the amorphized polymer, as measured from the surface downward into the bulk of the polymer, can be controlled. The polymer usually has a quasi-amorphous top surface having a depth of at least 5 nm, preferably at least 10 nm, more preferably at least 40 nm and most preferably at least 60 nm. The range of thickness for the quasi-amorphous phase or surface of the polymer may be from about 5 to 10,000 nm, preferably 10 to 1,000 nm, more preferably 20 to 500 nm or 20 to 100 nm and most preferably 20 to 250 nm, depending upon the ultimate use of the article.
The surface quasi-amorphous layer is firmly adhered to the bulk of the semicrystalline polymer because of the in situ nature of the conversion. There can even be a discernible gradation zone between the quasi-amorphous and semicrystalline areas, although this is not always the case. That is, the transition can be very abrupt within the polymer.
The portion of the surface area which is amorphized may be as small as 1% with some beneficial effects being noted. Generally it is at least 3%, and preferably 5 to 100% of the surface. More preferably at least 10% or 30 to 100% of the surface is quasi-amorphous. These are percentages by surface area.
In performing the process of making the quasi-amorphous surfaces of the present invention, the wavelength of the light or ultraviolet radiation and/or the polymer and/or absorbing dye in the polymer should be chosen so that the polymer composition exhibits an extinction coefficient greater than about 5,000. An absorption coefficient of 1/micrometer or preferably 5/micrometer is preferred. The higher the extinction coefficient for any given wavelength, the thinner is the surface layer which resides in the optical path of the radiation, and correspondingly, the thinner is the surface layer which undergoes a morphological transition or "amorphization". The wavelength range of preferred interest is between about 180 and 260 nm, with the highest extinction coefficient being manifested at the shorter wavelengths. Preferably a coefficient of extinction of at least 10,000 is exhibited by the polymer at the wavelength of irradiation.
When utilizing ultraviolet radiation (e.g., 193 nm), it is desired that the polyester film receives energy corresponding to a fluence of 3-25 mJ/cm 2 /pulse. At fluences of less than 3 mJ/cm 2 /pulse, the effect of the radiation is not readily discerned. At fluences greater than 25 mJ/cm 2 /pulse, one begins to encounter excessive damage to the affected surface layer, such as vaporization (e.g., off-gassing) of low molecular weight products of photodegradation, substantial reduction of the molecular weight of the surface layer, and more extensive surface roughening.
The radiation pulse duration, i.e., the pulse width, should be in the range of 10 nanoseconds to 100 microseconds to assure rapid excitation of the affected surface layer.
The net effects of pulse width, coefficient of extinction, and radiation intensity are to produce a particular type of mechanistic events. First, and to a minor degree, there is a photolytic effect in which absorbed radiation energy causes random bond scission to occur in the semicrystalline polymer. This effect is desirably minimized in the practice of the present invention to minimize the damage to polymer properties caused by this effect. Indeed, operation of the present invention under ideal conditions has been found to cause some decrease in the oxygen-to-carbon ratio, but sensitive ellipsometric and infrared measurements have been unable to detect any significant loss of material as a result of proper radiation conditions.
The second effect is a result of the unusual nature of the thermal excitation of the surface layer in the optical path of the radiation. Much of the absorbed light energy is translated into heat, with the heating cycle corresponding to the pulse width of the radiation. It is certain that instantaneous temperatures that exceed the normal melting point of the polymer (e.g., for poly(ethylene terephthalate that is about 260° C.) are reached throughout most of the affected volume, although an unusual thermal gradient may be produced within that volume because of the rapid attenuation of the incident energy due to light extinction by the polymer composition. The heat cycle thus corresponds to the pulse width, in a range of from about 10 nanoseconds to 100 microseconds. After the heating cycle, the next phenomic concern is the ensuing cooling cycle. Because of the thin nature of the affected volume and its contact with ambient air at the surface and bulk material (which are usually at room temperature), it can be estimated that the surface probably cools down to the glass transition temperature (e.g., for poly(ethylene terephthalate) this is about 75° C.) within microseconds. Once below this temperature, polymer chain conformations tend to be frozen. Considerations with respect to this unusually brief thermal cycle indicate that conformational changes available to the polymer chains remain highly restricted during the brief period while the affected surface area undergoes this excitation. Short segmental motions, e.g., of the `crankshaft` rotational type, have extremely short relaxation times, and it is expected that they may readily occur within the time-temperature regime created in the practice of the process of the present invention. The confirmation that such motions do indeed occur is provided by the IRRAS spectroscopic studies that show that there is a significant trans-to-gauche-conformer transformation in the surface layer which results from the irradiation of semicrystalline film (e.g., biaxially oriented poly(ethylene terephthalate)) with an ArF excimer laser.
This type of conformational change requires the rotation of a short segment of the PET chain involving only a few carbon or oxygen atoms. Similar considerations indicate that it is highly unlikely that the pre-existing crystallites or crystal lattices in the affected surface layer undergo any major spatial rearrangements because this time-temperature regime precludes the type of long range translational and large chain segment rotational motions which would materially change the pre-existing packing arrangement within the crystal lattice. Thus, it strongly appears that the pulsed UV irradiation of PET (and probably all semicrystalline polymers having appropriate extinction coefficients) provides films having surface layers with a unique morphology (i.e., quasi-amorphous) in which the polymer chains are highly disordered over short segment lengths, but substantially retain the long-range order that existed between chains and over long segment lengths of those chains prior to excitation. Indeed, the excimer laser treatment of a thin film of thermally crystallized PET indicated that the original spherulitic structure remained intact, tending to affirm this description.
The substantial trans-to-gauche-conformer transformation is a clear indication of short range chain conformation disordering, suggesting that although the crystallites may have undergone short range disordering, the longer range 3-dimensional packing order probably remains virtually intact. It is for this reason that the surface is referred to as quasi-amorphous since it has physical characteristics embodying some crystalline properties, and yet displays predominantly amorphous properties.
The volume of polymer affected or converted (i.e., the affected surface layer) by the process of the present invention is defined as being in a `quasi-amorphous` state because the highly ordered registry of identical chemical moieties in adjacent folds of the chain-folded crystal lattice is largely destroyed, but the overall 3-dimensional architecture of the crystal lattice is preserved. Thus, the chemical disordering which occurs as a result of the radiation is characteristic of an amorphous state, while the retention of longer range geometric order resembles a pseudo-crystalline state. The layers or regions are neither totally amorphous nor totally crystalline in the classic sense of those words. In this specification where quasi-amorphous layers or regions produced in the practice of the present invention are discussed, those regions may be referred to as quasi-amorphous layers or regions because their chemical properties tend to resemble amorphous compositions rather than crystalline compositions, but amorphous and quasi-amorphous are distinctly different as noted in the description of quasi-amorphous materials given above.
Quasi-amorphous is a state which is between semicrystalline and amorphous. It is more difficult to distinguish from a true amorphous state than a semicrystalline state, but a clear distinction can be drawn.
The quasi-amorphous layer must, of course, be formed from a semicrystalline state. The semicrystalline state may be a uniaxially oriented film, biaxially oriented film, or contain grossly unoriented crystallites (e.g., spherulitic crystallites randomly distributed throughout the film). When such a semicrystalline film is converted by the process of this invention (in whole or in part, as on one surface only) to the quasi-amorphous form, the quasi-amorphous areas will appear to be amorphous except that they will retain a latent memory for the crystallite orientation. This is a definitive distinction from the true amorphous state.
For example, oriented film will display anisotropy with respect to the absorption of infrared radiation (e.g. between 5,000 and 16,000 nm) in various directions in the film. Biaxially oriented film would most significantly display this anisotropy between the unoriented thickness dimension (e.g., the Z-axis) and the oriented length and width dimensions (e.g., the X- and Y-axes) of the film. When such an oriented film is quasi-amorphized according to the present invention to a state most closely resembling a true amorphous film (e.g., the entire thickness or a larger thickness is repeatedly treated without ablation of the film is quasi-amorphous), the film or layer will appear to be amorphous. However, the film or layer will not be truly amorphous because it will retain a latent memory for the crystallite orientation, in this case being evidenced by a latent memory for the anisotropic orientation of the original semicrystalline polymer.
When this quasi-amorphous layer or film is heated to promote recrystallization, the film or layer will begin to regain its original crystallite distribution or in the case of oriented film, regain at least part of its anisotropic orientation. When a truly amorphous layer is reheated, it will not develop anisotropy. Where the semicrystalline polymer film originally contained grossly unoriented crystallites, reheating of the quasi-amorphous layer or film would return such a crystallite orientation to the layer or film.
The process appears to work by the semicrystalline polymer's absorbing the energy of the irradiation within a limited depth of the irradiated surface. The energy is of sufficient intensity and duration to melt polymer, but of insufficient intensitiy and duration to evaporate, significantly chemically modify, or ablate polymer. When the irradiation stops, the melted polymer rapidly cools without recrystallization. No special cooling of the melted layer usually needs to be performed as the melted layer is usually sufficiently thin that ambient air and adjacent bulk polymer temperatures will cool it sufficiently rapidly. Forced cooling can be used on thicker layers if desired or can be used on thin layers to insure even more rapid cooling.
The semicrystalline polymer should be able to absorb the irradiation used in the process. The more highly absorptive the polymer is of the radiation, the greater the concentration of the process to the surface of the polymer. In general, the polymer should be able to absorb sufficient energy to cause thermal softening or melting of the surface and yet not absorb radiation at such a high level as would cause ablation, excessive degradation, or volatilization of the polymer. For example, a polymer may absorb at least 5% of incident radiation in a 1 micron thick film when the radiation is applied at a rate of 1 Joule/cm 2 . Absorption of the radiation may be enhanced by the addition of radiation absorbing dyes and pigments to the polymer. These, and other, radiation abosrbing materials can have some noticeable effect at levels as low as 0.05% by weight, but can also be used at higher levels, even up to 90% by weight and higher. For example, a polymer used to modify a pigment may be treated after it has been combined with the pigment. A generally preferred range would be from 0.1 to 50% by weight for such radiation absorbing additives.
The quasi-amorphous surface layer on the semicrystalline polymer base is unique because 1) it exists without substantial change of the surface chemical structure while the bulk properties of the polymer are unchanged, 2) it has a lower softening temperature than the semicrystalline polymer, which lower softening temperature allows auto adhesion at a temperature below that at which the bulk film would autoadhere, 3) it is more easily swelled by organic solvents which allows a high degree of bond entanglement with itself and with other coatings and polymers, 4) the controlled depth of amorphization serves to limit the depth of solvent penetration and hence limits the effect of solvents on the quasi-amorphous layer, and 5) it has a reduced optical index of refraction which is graded from the bulk to the surface.
The product used in the practice of the present invention has characteristics and features which tend to be different from those of the products of prior art processes. For example, it has been noted that the depth of the quasi-amorphous areas is at least five (5) nanometers. This tends to be an inherent result of the process. The previously referenced work reported by Wu concerning truly amorphous surfaces generated by non-crystallizable fractions being forced to the surface produces very thin amorphous layers. The thickness of these layers is never more than 3 nm and is usually less than 2 nm. Additionally, the chemical make-up of the surface region is significantly different from that of the bulk polymer because of the concentration of non-crystallizable fractions at the surface. The surface produced by this prior art phenomenon would have a weight average molecular weight more than 50% different from the weight average molecular weight of the associated bulk semicrystalline polymer. The surface produced by the practice of the present invention would have a difference of less than 50% between the weight average molecular weight of the surface quasi-amorphous layer and the bulk semicrystalline polymer.
Another characteristic of the treated materials used in the present invention which sometimes can be observed but is unique to those articles of the present invention is the similarity between the molecular orientation of the surface quasi-amorphous layer and the semicrystalline polymer in bulk. Polymer orientation relates to the degree to which polymer chains are statistically or more predominantly oriented within the polymer. Ordinarily, when semicrystalline polymers are melted, the orientation in the amorphous and crystalline phase is randomized and is significantly different from the orientation of semicrystalline polymer. Observations of the amorphized surfaces in the practice of the present invention indicate that the orientation within the quasi-amorphous layer remains similar to that of the semicrystalline polymer. Microscopic examination under cross-polarizers shows that the orientation of the quasi-amorphous layer is similar to or indistinguishable by visual observation from the orientation of the semicrystalline polymer. The physical properties of the quasi-amorphous layer, such as its index of refraction, infrared absorption spectrum and solubility clearly show that the layer is in fact in an amorphous-like state.
Corona discharge treatment of polymer surfaces does not necessarily render surfaces amorphous, but oxidizes the surface of the polymer. Corona treatment tends to have its most significant oxidative effect to a depth of about 2 nm. The corona treatment creates or adds functional groups to the polymer as a result of reactions with the environment in which the discharging is performed. For example, functional groups such as carboxylic groups, phenol groups, hydroxyl groups, carboxyl groups, and amide groups can be added to the polymer by the corona treatment. These groups would not be a direct product of the process of the present invention. Corona treatment of the amorphous surfaces of the present invention would generate such functional groups and would not necessarily crystallize the surface. Corona treatment also changes the optical density of the surface layer because of the formation of these new chemical materials in that surface. As compared to the bulk polymer, the optical density of the surface layer may increase by 0.2 within a 50 nm region of the visible portion of the electromagnetic spectrum (particularly in the yellow region).
Both corona discharge and flame treatment significantly modify the chemical composition of the polymer in the surface regions treated. Corona discharge tends to crosslink or degrade the polymer, creating a higher or lower crosslink density in the surface than in the bulk polymer. The article of the present invention, unless further treated as by corona discharge, will have approximately the same crosslink density in the amorphous surface layer as in the bulk polymer region. This change in crosslink density can be observed in the surface layer by a reduced tendency or ability to recrystallize. Plasma, and ion implantation treatments have effects on the crosslink density similar to those generated by corona discharge.
Flame treatment of polymeric surfaces (such as that reported in U.S. Pat. No. 4,568,632) is a much more destructive and chemical composition altering process than the process of the present invention. The patent describes the ablation of materials from the surface during treatment. This is probably the combined result of evaporation, oxidation, polymer chain breakage, and other destructive processes. This process would cause the formation of the functional groups described above and probably cause a significant overall change in the molecular weight and chemical make-up of the polymer on the surface, probably to a depth of about 2 nm. The flame treatment as presently practiced also causes a change in the optical density of the polymer on the surface due to the change in the chemical composition of that surface layer. That change in optical density is at least about 0.2. In the practice of the present invention, the quasi-amorphous layer produced on the surface has an optical density which is within 0.1, preferably within 0.08, more preferably within 0.05 and most preferably within 0.03 units of the bulk polymer. Additional treatment (e.g., corona discharge or coloration with dyes or pigments) could, of course, be used to change that value. But in the absence of dyes or pigments differentially distributed between the amorphous layer and the bulk layer, there should be little or no difference in optical densities.
In the preferred fluence range of the present invention, the most notable result is the formation of a new morphological state of the polymer within the surface layer (i.e., a quasi-amorphous, deoriented or oriented glass) which resides in the optical path of the radiation and begins at the surface of the polymer. This morphological transition is attended by some extremely mild degradation, as attested by the diminution of the O/C ratio (XPS analysis and solvent extraction data). The failure to detect weight loss by infrared and ellipsometric measurements indicates that gas evolution is, at most, a minor event. Similarly, IRRAS spectra shows evidence of only a morphological rather than any chemical change. The change in the O/C ratio is quite different from that occurring with flame treatment or corona discharge where the atom/atom, oxygen/carbon ratio increases. This increase may be very small, but in most thorough treatments there is a change in the ratio of about 0.1 or 0.2. The O/C ratio may actually decrease in the quasi-amorphous layer as compared to the bulk polymer.
The remarkable aspects of the preferred surface layer produced in this invention are: 1) its unchanged texture; 2) its unchanged optical absorption or scattering characteristics, and 3) its still appreciable molecular weight. Each of these aspects can be very important. For example, film roughness is very injurious in substrates for magnetic media because that roughness can be the limiting factor in the ultimate density of recorded information that can be achieved. Film yellowing or scattering (i.e., haze) on the other hand cannot be tolerated where the film is used as a substrate in the manufacture of imaging products, e.g., X-ray film. Finally, the absence of a major fraction of low molecular weight oligomeric products avoids the situation where subsequently applied functional coatings fail in use due to inherently poor adhesion or solvent resistance which stems from the weak boundary layer present at the coating/film interface.
The quasi-amorphous surface of the polymer also reduces the reflectivity of that surface. Normal, smooth uncoated polymer films will have a reflectivity of 10% or more. Highly texturized polymer surfaces can reduce this reflectivity, but cannot present a smooth surface, that is a surface having no texture which is easily visible with a scanning electron microscope at 10,000x magnification. The polymer films of the present invention can provide smooth surfaces with reflectivities of 9% or less to 550 nm light at 80°-90° incident angles. This is clearly shown in the Examples.
The process of the present invention also tends to not modify the surface of the polymer in a topographic morphologic sense. The surface structure, before and after amorphizing, tends to be the same in the practice of the present invention. Surfaces with a high degree of surface roughness may be somewhat softened in their features, but will still tend to have rough surfaces. Smooth surfaces will be substantially unchanged with respect to the absence of features on their surface. Flame treatment would tend to greatly modify the surface features of the surface so treated.
The process of producing this invention is an advance over prior methods of surface modification such as sputter etch, plasma, corona, chemical, flame and solvents because no vacuum is required, no contact with the surface is required, no chemistry is added to the treated polymer so that it is more likely to be recyclable, and there are no known environmental problems.
The surface properties of polymer films are of considerable importance to industry. These properties include adhesion, coefficient of friction, optical properties, wettability, and barrier properties. Modification of polymer surfaces to obtain these desired properties already can be realized by a number of different techniques. Many of these prior art processes can have adverse effects on the product, however. The more traditional "wet chemical" modification techniques, such as treatment with acids, amines, caustic, phenols or non-reactive liquids (i.e., solvents), have been successfully used to enhance the "wettability" and "bondability" of films and fibers. These chemical treatments can cause a temporary swelling of the polymer surface which results in a more reactive surface and on chemical evaporation this swelling subsides. These treatments can also result in a chemical modification of the surface by adding new substances, breaking the surface down to new substances, which also results in lower molecular weight polymer chains on the surface, or by cross-linking molecules on the surface.
With the increasing concern over environmental and safety issues, industry has looked toward a number of non-chemical surface modification techniques. Alternative techniques such as treatment with corona, plasma, sputter etch, E-beam, heat, UV, and lasers have been used to modify polymer surface properties. All of these treatments affect polymer surfaces in a fairly gross manner. With the exception of E-beam and heat, they all result in a roughened surface caused by removing material, and they all result in chemical modifications to the surface which are much like the changes from wet chemical treatments. None of these treatments affects the crystallinity of the polymer significantly without creating new surface chemistry. Table 1 is a summary of how various treatments affect polymer surfaces.
TABLE 1__________________________________________________________________________TREATMENT OF POLYMER SURFACES Surface Surface Purpose ofTreatment Texture Effect Treatment__________________________________________________________________________Corona Rough to Remove Material Priming Smooth Add Material Enhance Wettability Bond Scission Improve AdhesionPlasma Rough to Remove Material Priming Smooth Add Material Enhance Wettability 100-2000Å Crosslinking Improve AdhesionSputter-Etch Rogh Ablation Enhance Wettability 100-2000Å Change Chemistry Improve Adhesion Reduce Coefficient of Friction Reduce Optical ReflectanceHigh Intensity No change Chain Scission Curing Surface CoatsE-Beam Cross Linking Grafting Bulk Treatment Coating Adhesion Thick Layer High EnergyHeat No change Chain Scission Enhance Printability(Flame) Change Chemistry Form Barrier Layer Oxidation Thick LayerHigh Intensity Rough to Ablation PrimingUV Smooth Change Chemistry Enhance Wettability Improve Adhesion EtchingLaser Rough to Ablation Etching(prior art) Smooth Change Chemistry Priming Enhance Wettability Improve AdhesionLaser No change Amorphize Thin Reduce Optical(Present Layer ReflectanceInvention) Photolyze Increase Optical Transmission Improve Adhesion Improve Auto-Adhesion Reduce Coefficent of Friction Enhance e-Beam Grafting Barrier Layer Inc. Solubility of Crystalline Mtl. Grafting__________________________________________________________________________
Polymers generally can be either semicrystalline or amorphous. These categories are descriptions of the degree of ordering of the polymer molecules. Amorphous polymers consist of randomly ordered molecules. That is, the polymers are of low order or non-ordered and are independently surrounding and intertwined with other molecules. Semicrystalline polymers consist of a mixture of amorphous regions and crystalline regions. The crystalline regions are said to be more ordered and the molecules actually pack in some crystalline-like structures. Some crystalline regions may be more ordered than others. If crystalline regions are heated above the melting temperature of the polymer, the molecules become less ordered or more random. If cooled rapidly, this less ordered feature is "frozen" in place and the resulting polymer is said to be amorphous. If cooled slowly, these molecules can repack to form crystalline regions and the polymer is said to be semicrystalline. Some polymers are always amorphous. Some polymers can be made semicrystalline by heat treatments, stretching or orienting and by solvent inducement, and the degree of crystallinity can be controlled by these processes.
One aspect of the uniqueness of the present invention is the reversal of the above crystallization process to transform a thin surface layer of semicrystalline polymer into a quasi-amorphous thin surface layer residing on nonaffected bulk semicrystalline polymer.
There are two necessary conditions required of the radiation source to provide the treatment of the present invention. Both high intensity (high power per unit area) and high fluence (high energy density per pulse) are required of the radiation source. These requirements assure that a substantial amount of heat generated in the very thin surface of treatment stays in the surface. The effect of the radiation is to concentrate energy into the surface layer. Thermal diffusion into the bulk reduces this concentration of energy and makes the process less efficient. It is, therefore, desirable that only a small amount of heat be dissipated into the bulk of the polymer during irradiation. The more heat that is transfered to the bulk during the surface irradiation, the less efficient the process becomes until so much heat goes to the bulk that the process no longer works. Because of this requirement to rapidly heat only the surface layer and not the bulk of the polymer, conventional high intensity UV sources such as mercury arc lamps and common Xenon flash lamps with their inherently long pulse widths result in rapid diffusion of the thermal energy into the bulk polymer. This prevents a high concentration of energy being achieved at the surface.
The UV excimer laser is capable of producing high intensity, high fluence radiation on the surface of the polymer to be treated. The polymer used with a UV excimer laser must be semicrystalline and UV absorbing at the UV laser wavelengths. The result of the laser pulse interacting with the surface is a combination of photolyzation and heating. In other words, the short intense pulse significantly heats the surface of the polymer, but not the bulk, above the polymer melting temperature, and some surface molecule chain scission occurs. During the brief time the surface region is heated above its melting temperature, the molecules can randomize themselves into a disordered condition and broken bonds reconnect, although not necessarily to the same end from which they were broken or to the same degree. The temporarily broken molecular bonds will assist this melting process. After irradiation the surface layer will rapidly cool, and "freeze" the new disordered layer into an amorphous structure. That is, the cooling rate is fast enough so the surface layer cannot recrystallize. The irradiation thus produces an amorphous layer on the bulk polymer which layer undergoes only a small change in molecular weight because of the recombination of bond scissions and no chemical changes such as the addition of ions. The surface texture undergoes no significant change because no material has been removed or ablated and both melting and cooling occur over a short period of time.
The laser treated surface can be shown to be quasi-amorphous by a number of tests: 1) it washes off with solvents that only the amorphous form of the polymer is soluble in, 2) infrared reflection absorption spectroscopy (IRRAS) of the surface indicates the same pattern in the surface layer as is normally exhibited by the amorphous form of the polymer, and 3) thin film ellipsometry of the surface gives the same refractive index as does the amorphous form of the polymer.
XPS measurements of the treated surface indicates no significant chemical changes by addition. It also shows that a small O/C ratio change has occurred which indicates some small amount of surface decarboxylation. Gel permeation chromotography (GPC) shows only a small molecular weight decrease as compared to the untreated polymer. Water contact angle measurements show no change in the treated surface which means the surface has not been roughened significantly and that functionality groups have not been added. There is a slight texturing on an extremely fine scale. Shadow mask Transmission Electron Microscopy (TEM) indicates peaks and valleys on the surface of about 300 Å. This may account for the improved slip properties of the treated surfaces of this invention.
Early investigations of laser treatments of polymers were concerned with etching or ablation of the polymer and thus used laser intensites and fluences much higher than required for the present invention. These investigators found a fluence threshold for ablation which of course was different for each polymer treated. Below this threshold no ablation would take place. Investigation was never made to determine what actually was occuring at lower fluences. It has been found that like the fluence threshold for ablation, there is likewise a fluence threshold for the amorphization of this invention and it too varies with the polymer being treated.
Because of its great commercial interest, the treatment of PET has been studied most extensively during the progress of the present invention. However, other polymers have also been studied. The following semicrystalline, UV absorbing polymers or copolymers thereof have been treated: polyesters (e.g., PET), nylon, urethanes, coating mixtures of poly(vinylidene chloride) on PET and poly(vinyl chloride) with UV absorbing plasticizer added. Polypropylene, polyethylene (e.g., polyolefins), polyvinyl chloride, polytetrafluoroethylene and polyvinylidene chloride, although semicrystalline, are not UV absorbing at wavelengths greater than 190 nm, and therefore, require one of the following: the addition of UV absorbing compounds, shorter wavelength lasers, or an energy source different than a UV laser. E-beam, x-rays, ion beams, and plasmas, if applied in sufficient intensity and fluence can work on these polymers.
Polymethylmethacrylate and epoxies are already amorphous and so treatment is unnecessary and does not effect a differentiation between the surface and bulk polymer.
The UV radiation source can be by excimer laser or flashlamps at wavelengths less than 320 nm. The pulse widths should be less than 100 microseconds. Typical pulse widths are 7.5 microseconds for flash lamps and 10-80 nanoseconds for an excimer laser.
EXAMPLES
In the following examples all treatments were done using either a Model 2460 laser by Questek, Billerica, Mass. or a Model 102E laser by Lambda Physik of Acton, Mass. These lasers give equivalent outputs for the purposes of treating polymer films. The lasers were operated with either Ar plus Fluorine gas at an emission wavelength of 193 nm or with Krypton plus Fluorine gas at an emission wavelength of 248 nm and with a system of cylinderical lenses to control the exposed area of the sample and thus the energy density of the beam striking the sample. Each system was calibrated using a Model ED500 power meter by Gentech, Ste-Fog, Qc, Canada. Pulse width was approximately 15 nanoseconds for both lasers.
EXAMPLE 1
This example describes the treatment of a surface of 0.1 mm (4 mil) thick biaxially oriented polyethyleneterephthalate (PET) film with no slip agents added. This film is available as product #OR8478400 obtainable from 3M, St. Paul, Minn. After laser exposure each sample was measured for change in optical transmission at 550 nm using a Lambda 9 Spectrophotometer from Perkin Elmer (Norwalk, Conn.) with a 10 second response time. Untreated film was used as a control and measured 88.25% optical transmission. The following data shows the change in % transmission from this control value.
Table 2 shows the results and indicates an increase in optical transmission for PET films treated on one side at 193 nm and an apparent leveling off of the effect with increased fluence. This increasing and then leveling off is due to the depth of treatment increasing with increasing fluence. Also quite noticeable is the threshold effect wherein about 3 mJ/cm 2 /pulse fluence is required for the onset of this increased transmission. This fluence threshold is noticed on all effects measured for this laser treatment.
TABLE 2______________________________________ Exposure % Change inSample (MJ/cm.sup.2) Transmission (at 550 nm)______________________________________A 1 0B 2 0C 3 .03D 3 .08E 3 .10F 4 .18G 4 .37H 4 .45I 5 .58J 5 .78K 5 .82L 6 1.1M 7 1.4N 8 1.28O 9 1.40P 9 1.44Q 10 1.38______________________________________
Laser treatment of polymer films does not significantly change the absorptivity of the film at wavelengths greater than 350 nm. Therefore, increased transmission of laser treated films is a result of reduced reflectivity of the film and measurement of either effect is equivalent.
EXAMPLE 2
The example is a repeat of Example 1 with the exception that the laser gas was a mixture of Kr and F and the output wavelength was 248 nm.
The data indicated that there was no change in the optical transmission until fluence exceeded 5 mJ/cm 2 There was an increase of transmission to a peak change of 1.5%, reached at 9 mJ/cm 2 . The shift of the fluence threshold to a higher value of about 5 mJ/cm 2 /pulse (as compared to Example 1) which indicates a threshold dependence on the wavelength of the radiation used to treat the surface. This occurs because PET more efficiently absorbs 193 nm wavelength radiation than it does 248 nm wavelength radiation.
Excimer lasers operate efficiently at four different wavelengths: 193, 248, 308, and 351 nm. Efficient modification of the polymer requires that most of the UV radiation be absorbed in the first few tenths of a micrometer of of the surface. PET intensely absorbs both 193 and 248 nm. The efficiency of the surface modification also depends on the photolytic activity of the UV. Since 193 nm is more strongly absorbed than 248 nm and has higher photolytic activity, 193 nm radiation is slightly more efficient for surface modification. The threshold for surface modification of PET by excimer laser radiation (15 nanosecond pulse width) is 3 to 4 mJ/cm 2 /pulse for 193 nm and 5 mJ/cm 2 /pulse for 248 nm.
Excimer lasers produce roughly twice as much power at 248 nm than 193 nm. Since the threshold for surface modification at 248 nm is almost twice that of 193 nm, the net efficiency of surface modification between the two wavelengths is nearly equal. Therefore, the choice of the operating wavelength can be based on other factors.
The heat sealing process of the present invention can be best effected by heating the surface layer (the quasi-amorphous layer) during or immediately before contact with the surface to be bonded. This softens the layer, particularly when heated above Tg or the normal melting point. Upon cooling, the surface layer crystallizes and becomes indistinguishable from the bulk polymer, but is adhered to the other surface.
EXAMPLE 3
Samples of 0.1 mm (4 mil) PET as in Example 1 were treated with one 7.5 microsecond pulse from an L-2695 flashlamp by ILC Technology, Sunnyvale, Calif., with a peak current of 1700 amperes, 25 Joules of stored energy and a lamp to sample distance of 1.0 cm. Optical transmission measurements were made on the treated sample with a Lambda 9 Spectrophotometer and showed an increase in transmission over the measurement range of 340 nm to 700 nm and at 550 nm there was a 1.5% increase. This indicates intense short pulse UV rich flashlamps are also capable of forming amorphous surface on polymers.
EXAMPLE 4
Samples of crystalline polyetheretherketone were treated as in Example 1 at various fluences. Optical reflectivity of the treated samples was measured at 550 nm with a spectrophotometer as in Example 1. The data indicated a reduced reflectivity with increased fluence from 16 to 24 mJ/cm 2 /pulse, from 14.74% reflectivity to 14.60% reflectivity.
EXAMPLE 5
Samples of PET were treated as in Example 2 at fluences from 1 to 6 mJ/cm 2 /pulse and measured for auto adhesion properties. A model 12ASD heat sealer by Sentinal of Hyannis, Mass. at 350° F., 20 psi sealing pressure and a 3 second dwell time was used to seal the treated surfaces to each other. Bond strength was measured by peeling the samples 180° apart by hand and judging the relative peel strength resulting from various fluences The data showed increased adhesion above a fluence of 4 mJ/cm 2 /pulse. The film had slight adhesion without treatment, and increased to good adhesion at about 6 mJ/cm 2 /pulse.
These data are very similar to those for % increase in transmission of Example 2 and shows substantially the same fluence threshold. This strongly implies that the amorphous surface created by this invention causes both effects
EXAMPLE 6
Samples of PET were treated as in Example 1 and measured for autoadhesion properties. A model 12ASD heat sealer by Sentinal of Hyannis, Mass. at 350° F., 20 psi sealing pressure and a 3 second dwell time was used to seal the treated surfaces to each other. Bond strength was measured by peeling the samples 180° apart by hand and judging the relative peel strength resulting from the various treatments. Since moisture is known to affect the bond strength of PET treated by other methods, each sample was tested both dry and under running water. Bond strengths were classified as follows: A weak bond was peelable without polymer film failure, a medium bond had a higher peel strength and occasional polymer film failure and a strong bond is not peelable and resulted in polymer film failure. These semiquantitative results are plotted in the FIGURE.
It is well known in the literature of continuous wave, low to moderate intensity UV lamps, that surface modification of polymers is energy density insensitive. That is, if for example, 100 mJ/cm 2 is required to modify a polymer in a certain manner, it doesn't matter if that energy density is obtained by using an intensity of 100 watts/cm 2 for 1 second or 50 watts/cm 2 for 2 seconds and it has always been assumed that this was inviolate up to the energy region required for photoablation. The line indicating constant energy density of the FIGURE illustrates this conventional wisdom and is substantiated by experiments up to a certain fluence.
The surprising discovery of this invention is that at a certain threshold fluence, in this case 3.5 mJ/cm 2 /pulse, there is an enormous decrease in energy density required to produce auto adhesion. The explanation of this phenomenon is believed to be that at low fluences, auto adhesion is the result of oxidation of the surface layer, whereas above the threshold fluence an amorphous surface layer is created with a lower softening temperature than the bulk polymer which results in the increased auto adhesion. It can be seen that in the region of ablation or microtexturing, the auto adhesion for this polymer is also very strong. This is another surprising discovery of this invention and is due to a reduced softening temperature of structures generated on the polymer surface.
From the FIGURE, it is apparent that amorphization can be achieved with one pulse if the fluence level is within certain ranges, and increasing the number of pulses at a particular fluence increases the depth of treatment until at too high a pulse count the polymer starts to photo degrade significantly.
EXAMPLE 7
Samples of PET as in Example 1 were treated with various exposure to a CW short wave UV from a 6 watt model ENF-26 Spectronics lamp of Westbury, N.Y. The lamp was placed directly on the polymer surface for 1 minute, 15 minute, and 35 minutes. The exposed samples and an unexposed control were then sealed to themselves using a Model 12ASD heat sealer from Sentinal of Hyannis, Mass. set at 350° F., 20 psi sealing pressure for 3 seconds. Auto adhesion bond strength was measured by peeling the sealed samples 180° apart by hand and judging the resulting relative peel strength. Samples were also tested under running water for moisture bond strength. The results are shown in Table 3.
TABLE 3______________________________________Exposure Adhesion Moisture Sensitivity______________________________________0 min no adhesion NA1 min no adhesion NA15 min moderate adhesion yes35 min moderate adhesion yes______________________________________
Auto adhesion of PET from CW UV lamps is caused by surface oxidation and as can be seen gives a very different bond than PET laser treated as in Example 6.
EXAMPLE 8
A sample of PET was treated with short pulse UV flashlamps as in Example 3. A hand sealing iron at 145° C. was used to bond two samples to each other for six seconds. The samples showed good adhesion by attempting to peel the sample apart with a 180° hand pull. The bond was similarly tested under running water and was found to be moisture insensitive.
EXAMPLE 9
Samples of 0.038 mm (1.5 mil.) Nylon 66 from Allied Corp., Morristown, N.J., Product ID Capran-996 was exposed to one pulse of 25 mJ/cm 2 as in Example 1. The samples were bonded to each other using a fiberglass covered hand sealing iron at 143° C. for 6 seconds. Untreated control samples showed no auto adhesion while the exposed samples showed good adhesion by attempting to peel them apart with a 180° hand pull. The samples were boiled in water for 15 minutes and there was little to no perceptible decrease in bond strength.
EXAMPLE 10
Samples of PET were treated at two pulses at 5 mJ/cm 2 /pulse as in Example 1. These PET samples were bonded to the treated Nylon 66 samples of Example 9 using the same sealing conditions as Example 9. Peel tests using a 180° hand pull indicated good adhesion between the samples.
EXAMPLE 11
Samples of a coated PET film were treated as in Example 1. The coating was 0.002 mm (0.08 mil) of a solution of a copolymer of 75% polyvinylidene dichloride (PVDC) and 25% acrylonitrile and was coated on 0.0127mm (0.5 mil) PET. This film product is available as Scotchpar 86096 from 3M, St. Paul, Minn. At about 130° C. the coated side of this film is normally autoadhesive. This example shows the reduced temperature required to produce autoadhesion by first treating it with a UV laser. The samples were sealed to themselves at 110° C., 20 psi and 3 seconds dwell time using a model 12ASD Sentinal heat seater from Hyannis, Mass. The bonds were tested using a 180° hand pull and the results are shown in Table 4.
TABLE 4______________________________________Sample Fluence # Pulses Bonding Results______________________________________A 3.0 5 slightB 3.5 5 tackC 4.1 5 excellent-film failureD 4.7 5 excellent-film failureE 5.5 5 excellent-film failureF 7.8 5 excellent-film failureG 10.4 5 excellent-film failureH Control 0 0 easily peeled______________________________________
As can be seen, above the fluence threshold of about 4 mJ/cm 2 /pulse, the bond strength was excellent and the peel test caused the film to fail. This example also shows that the of a U.V. absorber allows amorphatization of a normally non-UV absorbing crystalline polymer (PVDC). | Semicrystalline polymers can have predetermined amounts of their surfaces rendered quasi-amorphous by irradiation. Polymer surfaces which are so modified can display enhanced heat sealability to accept bonding to other materials. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and a method for controlling a sewing machine driven by a drive such as a motor.
2. Description of the Background Art
FIG. 62 is an arrangement diagram showing a conventional sewing machine controlling apparatus disclosed in Japanese Laid-Open Patent Publication No. HEI3-14479, for example. In this drawing, the numeral 1 indicates a sewing machine, 2 denotes a motor, 3 designates a needle position detector acting as needle position detection means to detect the needle position of the sewing machine 1, 4 represents a machine pulley, 5 indicates a motor pulley, and 6 represents a belt fitted over the machine pulley 4 and the motor pulley 5 to transmit the rotation of the motor 2 to the sewing machine 1. 7 designates a stator of the motor 2, 8 denotes a rotor of the motor 2, and 9 indicates a brake for stopping the motor 2. 10 denotes a foot pedal used to operate the sewing machine 1, 11 represents a lever unit which detects the operation of the foot pedal 10, 12 designates a sewing machine control circuit serving as machine control means to control the orientation, automatic thread trimming, backtacking, etc., of a machine needle, and 13 indicates a motor speed control circuit acting as motor speed control means to control the motor 2 and the brake 9, thereby providing desired stitching speed under the operation command of the foot pedal 10 and others.
S1 indicates a stitching start signal, S2 designates a thread trimmer start signal, S3 represents a needle UP signal, VC denotes a speed command signal, SRT indicates a run signal, BK represents a brake signal, LLKO denotes a low-speed command signal, IMCO designates a middle-speed command signal, and R indicates a reverse rotation signal. It is to be understood that the stitching start signal S1 and the thread trimmer start signal S2 are input signals from the lever unit 11 to the sewing machine control circuit 12, the speed command signal VC is an input signal from the lever unit 11 to the motor speed control circuit 13, and the run signal SRT, the brake signal BK, the low-speed command signal LLKO, the middle-speed command signal IMCO and the reverse rotation signal R are command signals from the sewing machine control circuit 12 to the motor speed control circuit 13.
The operation of the conventional apparatus arranged as described above will now be described. An operation timing chart is shown in FIG. 63. Toeing down the foot pedal 10 switches the stitching start signal S1 on, outputs the run signal SRT from the sewing machine control circuit 12 to the motor speed control circuit 13, excites the stator 7 of the motor 2, and rotates the rotor 8 to drive the sewing machine 1 via the motor pulley 5, the belt 6 and the machine pulley 4.
Then, by changing the toe-down amount of the foot pedal 10, the voltage, current and frequency applied by the motor speed control circuit 13 to the stator 7 of the motor 2 are under the control of the speed command signal VC of the lever unit 11 and the position detection signal FG of the needle position detector 3 fitted to the sewing machine 1 to control the speed of the sewing machine 1 to a desired value according to the toe-down amount of the foot pedal 10.
When the foot pedal 10 is returned to a neutral position, the low-speed command signal LLKO for positioning is output by the sewing machine control circuit 12, and simultaneously, the needle UP or DOWN of the sewing machine 1 is detected under the control of the position detection signal (UP or DOWN) of the needle position detector 3, and the magnetic brake 9 is excited to stop the sewing machine 1.
Further, when the foot pedal 10 is heeled, i.e., is turned in the direction opposite to the tow-down direction, the thread trimmer start signal S2 is switched on, the machine control circuit 12 outputs the run signal SRT and the middle-speed command signal IMCO to carry out end backtacking. After the end backtacking is finished, the middle-speed command signal IMCO is switched off, the low-speed command signal LLKO is switched on, and a thread trimmer output is provided to trim the machine threads.
The needle position detector 3 outputs the needle UP position signal UP and needle DOWN position signal DN which represent the positions of the machine needle. The outputs of this needle position detector 3 and the lever unit 11 are provided to the sewing machine control circuit 12 which exercises the speed control of the motor 2 and the control of various solenoids (not shown) of the sewing machine 1.
The motor speed control circuit 13, which contains an inverter, switches between phases to reverse the motor 2 for the following reason. In the automatic thread trimmer mechanism of the sewing machine 1, since the machine threads are typically trimmed using the rotation of the machine spindle after the machine needle has moved away from a material to be sewn, risen, and reached the highest position or a top dead center, the position where the sewing machine is braked to a stop after machine thread trimming and needle position detection is considerably lower than said top dead center. Hence, when the machine needle stops at this low position if the sewing machine rotates in a forward direction only, the material moved in/out, for example, is caught by the machine needle. To prevent this, the pedal 10 is operated to perform thread trimmer operation to cut the machine threads, the needle position is then detected, and the sewing machine is braked to a stop, whereby if the machine needle stops at the low position, the motor 2 is further reversed to return the machine needle nearer to the top dead center and stop there, and therefore, even a heavy material to be stitched is not caught by the machine needle. It is to be understood that when the machine needle is not at the UP position, the needle UP signal S3 is given to run the sewing machine forward to rotate the machine needle to the UP position. When the machine needle is not at the UP position at power-on, the sewing machine is run forward to rotate the machine needle to the UP position if the needle UP signal S3 is not provided.
The operation of the sewing machine control circuit 12 will now be described in accordance with FIG. 64. The sewing machine control circuit 12 consists of microprocessor circuits (not shown) such as a CPU, ROM, RAM and I/O ports, and is under the control of software. When the pedal 10 is toed down to provide the stitching start signal S1 to a run signal input circuit 301, the run signal SRT is output from a rotation/stop command circuit 305 to the motor speed control circuit 13 via a run control circuit 300 to start the motor 2 running.
Subsequently, when the pedal 10 is returned to the neutral position, the run control circuit 300 outputs the low-speed command signal LLKO to the motor speed control circuit 13 via a speed command circuit 304, whereby the motor 2 is controlled to run at low speed.
Detecting that the sewing machine 1 has reached or exceeded a predetermined speed via a needle UP/DOWN position input circuit 302 according to the pulse width of the needle DOWN position signal DN and that the needle DOWN position signal DN has entered, the run control circuit 300 switches the run signal SRT off and switches the brake signal BK on for a given period of time via the rotation/stop command circuit 305.
Then, when the pedal 10 is heeled to switch on the thread trimmer start signal S2, the middle-speed command signal IMCO is output via the run control circuit 300 and the speed command circuit 304, whereby the motor 2 runs at middle speed, backtacking is performed, the middle-speed command signal IMCO is then switched off, and further the low-speed command signal LLKO is switched on, causing the motor 2 to run at low speed. When the needle DOWN position signal DN is switched on, the thread trimmer output T is provided by a solenoid control circuit 303 to conduct automatic thread trimming of the sewing machine 1. When the needle UP position signal UP is detected, the run signal SRT is switched off, and the brake signal BK is switched on for a given length of time via the rotation/stop command circuit 305, the solenoid control circuit 303 switches the thread trimmer output T off and a wiper output W on for a given period of time, stopping the sewing machine at a thread take-up lever top dead center. It is to be understood that the thread take-up lever top dead center indicates that the thread take-up lever (not shown), which feeds the needle thread of the sewing machine 1, is at the top position, where the thread has been fed the most and cannot be removed from the machine needle at the start of next stitching.
After the brake signal BK has been excited for a given length of time, the reverse rotation signal R is switched on and the run signal SRT is switched on to reverse the motor 2. When the needle top dead center is detected using the needle UP position signal UP, the run signal SRT is switched off and the brake signal BK is switched on for a given period of time to stop the sewing machine at the needle top dead center, and the brake signal BK is switched off. Subsequently, when the thread trimmer start signal S2 is on, the solenoid control circuit 303 outputs a presser foot UP output FU to raise the presser foot (not shown).
FIG. 65 shows an example of needle bar motion, wherein a vertical axis represents the height of the machine needle with respect to a throat plate surface (0 mm) and a horizontal axis represents the rotary angle of an arm shaft (not shown) of the sewing machine 1. As the arm shaft of the sewing machine 1 rotates, the height of the machine needle changes.
At the position of 0 degrees in FIG. 65, for example, the machine needle is at the top dead center and is out of the material, whereby the material can be removed. At the position of 180 degrees, the machine needle is at the bottom dead center. When it is desired to change the direction of the material to change the stitching direction, the machine needle stopping at this position allows the material to be turned without being offset.
At the position of 90 degrees, the machine needle sticks in the material. At the position of 100 degrees, the machine needle is located at the position of the throat plate (not shown) where the material is placed. The machine needle comes out of the throat plate surface at the position of 260 degrees and comes out of the material at the position of 270 degrees.
The UP position signal UP of the machine needle is switched on slightly in front of the thread take-up lever top dead center (at 40 degrees) and the DOWN position signal DN of the machine needle is switched on slightly in front of the needle DOWN position (at 160 degrees). The machine needle is oriented to a stop at the needle UP or DOWN position under the control of these two signals.
SUMMARY OF THE INVENTION
In the conventional sewing machine controlling apparatus arranged as described above, when the sewing machine is started with the machine needle stopping at the UP position after thread trimming or the like, the sewing machine 1 is not high in speed and does not have the force of inertia when the machine needle pierces the material as compared to the start of operation with the machine needle at the DOWN position, whereby the machine needle does not pierce a heavy material, a leather product or the like.
For this reason, the machine pulley is reversed by hand and brought near to the needle DOWN position before operation is started, whereby the material must be held by one hand at the start of stitching, workability is low, and it is dangerous to touch the machine pulley.
When the material to be sewn is a leather product, for example, in which large holes are made in seams, the holes, if positioned inaccurately from the edges of the leather, will result in unneat seams and low quality. To avoid this, the machine pulley is turned by hand to move the machine needle to a position immediately before the material, the positions of holes made by the machine needle in the leather product are determined, and operation is then started, whereby the material must be held by one hand, resulting in poor workability. In addition, if the pedal is accidentally depressed by foot during the hand-turning of the machine pulley, the sewing machine may rotate and the operator hand will be caught between the machine pulley and the belt, etc., involving danger of injury.
Also, if the machine needle is moved to the position immediately before the material once, the position where the machine needle should stick in the material cannot always be reached at one time and the machine pulley must be hand-rotated in the forward or reverse direction several times to set the position, further reducing workability.
Also, when a switch is turned on by hand to start stitching, the hand holding the material is used to turn the switch on, whereby the material moves and stitching start must be repeated many times.
Also, in jogging angle setting, a jogging angle is set by angle setting means, a jogging signal is entered to rotate the sewing machine by the jogging angle, a distance between the material and the machine needle is checked, and if the distance is too short or too long, the angle setting must be repeated many times.
Also, when the material to be stitched has been changed, the angle is re-set, the jogging signal is entered to make a rotation of the jogging angle, the distance between the material and the machine needle is checked, and if the distance is too short or too long, the angle setting must be repeated many times.
It is accordingly a first object of the present invention to overcome the above enumerated difficulties by providing a safe sewing machine controlling apparatus and method which allow the machine needle to be stopped immediately before a material by the rotation of a drive, such as a motor, to permit pre-microadjustment of the position where the machine needle sticks in the material and which allow the sewing machine to be reversed to return the machine needle to pierce even a heavy material.
A second object is to provide a sewing machine controlling apparatus and method which permit reverse-rotation needle UP for use with a blind stitching machine and which also permit reverse-rotation needle UP after backtacking when it is desired to do backtacking.
A third object is to provide a sewing machine controlling apparatus and method which keep any excess stitches from being put in a material or a finger from being stuck during needle UP operation.
A fourth object is to provide a sewing machine controlling apparatus and method which allow a next thread trimmer signal to be entered when the machine needle has stopped at the UP position and the force of piercing a material to be increased at the start of operation to pierce even a heavy material without requiring the machine pulley to be rotated by hand.
A fifth object is to provide a sewing machine controlling apparatus and method which allow a next thread trimmer start signal to be entered after thread trimming and the force of piercing a material to be increased at the start of operation to pierce even a heavy material without requiring the machine pulley to be rotated by hand.
A sixth object is to provide a sewing machine controlling apparatus and method which offer ease of determining the position of sticking the machine needle without the machine pulley being rotated by hand after thread trimming, whereby excellent workability is increased, stitching time is reduced, and the machine pulley need not be touched by hand.
A seventh object is to provide a sewing machine controlling apparatus and method which keep a material from being offset in pressing a switch by hand to avoid stitching start from being repeated many times, whereby workability is increased and stitching time is reduced.
An eighth object is to provide a sewing machine controlling apparatus and method which facilitate jogging angle setting which must be made to change the stopping position of the machine needle immediately before a new material different in thickness from the old one.
As described herein, according to the first feature of the invention, the jogging angle can be set and the machine needle can be stopped immediately before the material by the sewing machine drive so that the machine pulley need not be hand-turned, whereby safety is ensured and working efficiency is improved.
Also, according to a second feature of the invention, the application of the jogging signal allows the machine needle to be rotated in the reverse direction to a position away from the material, whereby the stitching start speed of piercing the next material is increased and the force of inertia is large enough to prevent the needle from being stopped, without piercing the material, and working efficiency is improved. Also, the torque of the sewing machine drive may be small, resulting in a low-priced apparatus.
Also, according to a third feature of the invention, the application of the jogging signal alternates forward rotation and reverse rotation, whereby the position where the material is pierced with the machine needle can be readjusted easily.
Also, according to the fourth embodiment of the invention, the application of the stitching start signal after the forward rotation of the jogging angle automatically rotates the sewing machine in the reverse direction once, then in the forward direction, whereby the force of piercing the material can be provided and the jogging signal need not be applied to improve working efficiency.
Also, according to the fifth embodiment of the invention, the stitching start signal causes the sewing machine to rotate in the reverse direction, come to a stop once, then rotate in the forward direction, whereby skip stitches or the like caused by the unevenly fed thread when the reverse rotation shifts directly to the forward direction can be prevented because the sewing machine rotates forward after the thread is fed evenly.
Also, according to the sixth embodiment of the invention, if the sewing machine does not rotate forward by the jogging angle when the jogging signal has been applied, the stitching start signal causes the sewing machine start with forward rotation, not with reverse rotation, whereby working efficiency is improved.
Also, according to the seventh embodiment of the invention, after operating under the control of the stitching start signal, the sewing machine is always rotated forward by the jogging angle in the forward direction under the control of the jogging signal, whereby working efficiency is improved.
Also, according to the eighth embodiment of the invention, reverse-rotation needle UP can be achieved when the direction of the material is changed on the blind stitching machine, whereby the machine pulley need not be hand-rotated to improve working efficiency.
Also, according to the ninth embodiment of the invention, the reverse rotation signal permits reverse-rotation needle UP and the thread trimmer start signal allows end backtacking and reverse-rotation needle UP, whereby working efficiency is improved.
Also, according to the tenth embodiment of the invention, reverse-rotation needle UP is performed before the material is pierced with the machine needle and forward-rotation needle UP is done after the material has been pierced, whereby the material is not seamed or bored unlike the conventional sewing machine which always rotated forward. Also, since the machine needle always moves upward, there is no danger that the hand is pierced with the machine needle if it is under the machine needle, ensuring safety.
According to the eleventh embodiment of the invention, the material is not seamed or bored unlike the conventional sewing machine which automatically raised the needle in the forward direction at power-on. Also, the finger is not pierced.
Also, according to the twelfth embodiment of the invention, since the sewing machine is designed to rotate the jogging angle only after thread trimmer operation is performed, the needle is usually at a stop at the DOWN position before thread trimming, and if the jogging signal switch is accidentally touched, the sewing machine does not rotate when the needle need not stop immediately before the material, and if the sewing machine is jogged carelessly, for example, the machine needle is kept from coming out of the DOWN position and stopping at a position outside the material, the material does not offset when its direction is changed, neat seams are provided, and unnecessary motion is not made, whereby time can be reduced and working efficiency is improved.
Also according to the thirteenth to the fifteenth embodiments, the application of the stitching start signal at the needle UP position stop time or after thread trimming causes the machine needle to rotate in the reverse direction by the reverse rotation angle set to the reverse rotation angle setting means, then to rotate in the forward direction, whereby the speed at the time of piercing the material is increased enough to provide the force of inertia, thereby preventing the needle from stopping without piercing the material. Also, the motor torque may be small, resulting in a low-priced apparatus.
Also, according to the sixteenth embodiment, the jogging angle can be set and the machine needle can be stopped immediately before the material by the sewing machine drive, whereby the machine pulley need not be hand-turned to ensure safety and improve working efficiency.
Also, according to the seventeenth embodiment of the invention, when it is desired to change the material position or the material after the machine needle has been lowered to the position immediately before the material once, merely entering the jogging signal causes the machine needle to rotate reversely to return to the top, whereby it is easy to shift the material position or change the material.
Also, according to the eighteenth embodiment of the invention, the wiper, if any, makes contact with the machine needle when the thread is wiped by the wiper after the machine needle has stopped immediately before the material, and to prevent this, the sewing machine is stopped once at the needle UP position, the wiper is operated, and the sewing machine is rotated the jogging angle again to stop the machine needle at the position immediately before the material, whereby the wiper does not come into contact with the machine needle and the needle fall position for the next material can be adjusted easily.
Also, according to the nineteenth embodiment of the invention, the machine pulley is hand-turned until it actually reaches the stop position immediately before the material and that position is stored, whereby angle setting need not be repeated many times.
Also, according to the twentieth embodiment of the invention, the number of times when the reverse rotation signal switch is pressed is decreased to reduce working time.
Also, according to the twenty first embodiment of the invention, the reverse rotation signal switch can be omitted, resulting in a low-priced apparatus.
Also, according to the twenty second embodiment of the invention, the sewing machine is actually rotated under the control of the ultra-low speed signal, with the machine pulley untouched, to match the point of the machine needle with the position immediately before the material, whereby safety is ensured, adjustment need not be made many times, and working time is reduced.
Also, according to the twenty third embodiment of the invention, the sewing machine running at ultra-low speed can be returned under the control of the angle storage signal if it has gone beyond the destination, whereby the time for setting the position immediately before the material is reduced.
Also, according to the twenty fourth embodiment of the invention, once the angle between the material and the machine needle has been set, the stop position immediately before the material need not be re-adjusted if the thickness of the material changes, whereby working time can be reduced.
Also, according to the twenty fifth embodiment of the invention, the torque which peaks within the position where the material is pierced with the machine needle is removed as noise, whereby the material surface position can be detected reliably.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an arrangement diagram of a sewing machine controlling apparatus illustrating an embodiment of a first embodiment of the invention.
FIG. 2 is a detail drawing of a sewing machine control circuit shown in FIG. 1.
FIG. 3 is a flowchart illustrating the operation of the first embodiment of the invention.
FIG. 4 is a timing chart of the first embodiment of the invention.
FIG. 5 is a flowchart illustrating the operation of a second embodiment of the invention.
FIG. 6 is a timing chart of the second embodiment of the invention.
FIG. 7 is a timing chart of a third embodiment of the invention.
FIG. 8 is a flowchart illustrating the operation of a fourth embodiment of the invention.
FIG. 9 is a timing chart of the fourth embodiment of the invention.
FIG. 10 is a flowchart illustrating the operation of a fifth embodiment of the invention.
FIG. 11 is a timing chart of the fifth embodiment of the invention.
FIG. 12 is a timing chart of a sixth embodiment of the invention.
FIG. 13 is a timing chart of a seventh embodiment of the invention.
FIG. 14 is an arrangement diagram of a sewing machine controlling apparatus illustrating an eighth embodiment of the invention.
FIG. 15 is a diagram showing a stitching pattern of the eighth embodiment of the invention.
FIG. 16 is a detail drawing of a sewing machine control circuit shown in FIG. 14.
FIG. 17 is a flowchart illustrating the operation of the eighth embodiment of the invention.
FIG. 18 is a timing chart of the eighth embodiment of the invention.
FIG. 19 is a flowchart illustrating the operation of a ninth embodiment of the invention.
FIG. 20 is a timing chart of the ninth embodiment of the invention.
FIG. 21 is an arrangement diagram of a sewing machine controlling apparatus illustrating an embodiment of a tenth embodiment of the invention.
FIG. 22 is a detail drawing of a sewing machine control circuit shown in FIG. 21.
FIG. 23 is a flowchart illustrating the operation of the tenth embodiment of the invention.
FIG. 24 is a needle bar motion diagram of the tenth embodiment of the invention.
FIG. 25 is a timing chart at the time of reverse-rotation needle UP in the tenth embodiment of the invention.
FIG. 26 is a timing chart at the time of forward-rotation needle UP in the tenth embodiment of the invention.
FIG. 27 is a flowchart illustrating the operation of an eleventh embodiment of the invention.
FIG. 28 is a flowchart illustrating the operation of a twelfth embodiment of the invention.
FIG. 29 is an arrangement diagram of a sewing machine controlling apparatus illustrating a thirteenth embodiment of the invention.
FIG. 30 is a detail drawing of a sewing machine control circuit shown in FIG. 29.
FIG. 31 is a timing chart of the thirteenth embodiment of the invention.
FIG. 32 is a flowchart illustrating the operation of the thirteenth embodiment of the invention.
FIG. 33 is a flowchart illustrating the operation of a fourteenth embodiment of the invention.
FIG. 34 is an arrangement diagram of a sewing machine controlling apparatus illustrating a fifteenth embodiment of the invention.
FIG. 35 is a detail drawing of a sewing machine control circuit shown in FIG. 34.
FIG. 36 is a timing chart of the fifteenth embodiment of the invention.
FIG. 37 is a flowchart illustrating the operation of the fifteenth embodiment of the invention.
FIG. 38 is a timing chart of a sixteenth and seventeenth embodiment of the invention.
FIG. 39 is a flowchart illustrating the operation of the sixteenth and seventeenth embodiment of the invention.
FIG. 40 is a timing chart of the and eighteenth embodiment of the invention.
FIG. 41 is a flowchart illustrating the operation of the eighteenth embodiment of the invention.
FIG. 42 is an arrangement diagram of a sewing machine controlling apparatus illustrating an nineteenth embodiment of the invention.
FIG. 43 is a detail drawing of a sewing machine control circuit shown in FIG. 42.
FIG. 44 is a flowchart illustrating the operation of the nineteenth embodiment of the invention.
FIG. 45 is a timing chart of the nineteenth embodiment of the invention.
FIG. 46 is a flowchart illustrating the operation of a twentieth embodiment of the invention.
FIG. 47 is a timing chart of the twentieth embodiment of the invention.
FIG. 48 is a flowchart illustrating the operation of a twenty-first embodiment of the invention.
FIG. 49 is a timing chart at a time when the sewing machine pulley of the twenty-first embodiment of the invention has been rotated a given angle or more.
FIG. 50 is a timing chart at a time when the sewing machine pulley of the twenty-first embodiment of the invention has been rotated less than the given angle.
FIG. 51 is an arrangement diagram of a sewing machine controlling apparatus illustrating a twenty-second embodiment of the invention.
FIG. 52 is a detail drawing of a sewing machine control circuit shown in FIG. 51.
FIG. 53 is a flowchart illustrating the operation of the twenty-second embodiment of the invention.
FIG. 54 is a timing chart of the twenty-second embodiment of the invention.
FIG. 55 is a flowchart illustrating the operation of a twenty-third embodiment of the invention.
FIG. 56 is a timing chart of the twenty-third embodiment of the invention.
FIG. 57 is an arrangement diagram of a sewing machine controlling apparatus illustrating a twenty-fourth embodiment of the invention.
FIG. 58 is a detail drawing of a sewing machine control circuit shown in FIG. 57.
FIG. 59 is a flowchart illustrating the operation of the twenty-fourth embodiment of the invention.
FIG. 60 is a timing chart of a twenty-fifth embodiment of the invention.
FIG. 61 is a flowchart illustrating the operation of the twenty-fifth embodiment of the invention.
FIG. 62 is an arrangement diagram of a conventional sewing machine controlling apparatus.
FIG. 63 is a timing chart of conventional operation.
FIG. 64 is a detail drawing of a sewing machine control circuit shown in FIG. 62.
FIG. 65 is a diagram showing an example of the needle bar motion of the sewing machine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the invention will now be described with reference to the appended drawings. FIG. 1 is an arrangement diagram of a sewing machine controlling apparatus concerned with the present embodiment, wherein the numeral 30 indicates a jogging angle setting circuit acting as jogging angle setting means, 520 represents a sewing machine control circuit detailed in FIG. 2, and S4 designates a jogging signal entered into the sewing machine control circuit 520. A position detection signal FG from the needle position detector 3 is designed to be entered into the motor speed control circuit 13 and also into the sewing machine control circuit 520. It is to be noted that the other parts are identical to those of the conventional example in FIG. 62 and will not be described.
The operation of the apparatus according to the present embodiment will now be described. When the jogging angle is set to 90 degrees, for example, by the jogging angle setting circuit 30 and the jogging signal S4 is applied to the sewing machine control circuit 520, the sewing machine 1 runs in the forward direction by the set jogging angle and the machine needle stops immediately before the material.
When the jogging signal S4 is switched on, the run signal SRT is switched on via the run signal input circuit 301 in FIG. 2, then via the run control circuit 330 and the rotation/stop command circuit 305 to start the motor 2 running forward. At this time, the jogging angle set in the angle setting circuit 30 is compared by an angle comparison circuit 311 with the rotary angle of the sewing machine 1 entered to the needle position input circuit 312 from the position detection signal FG given by the needle position detector 3. If the rotary angle has reached or exceeded the set jogging angle, the run control circuit 330 causes the rotation/stop command circuit 305 to switch the run signal SRT off and the brake signal BK on, stopping the sewing machine 1 at the rotary position of the set jogging angle.
The above operation will be described in accordance with a flowchart in FIG. 3. At power-on or after thread trimming, a flag S4ONF for storing the ON of the jogging signal S4 has been cleared to 0, the run signal SRT to OFF, and the brake signal BK to OFF.
Starting at step 40, the processing advances from step 41 to step 42 because the flag S4ONF is still 0 at step 41. Until the jogging signal S4 turns from OFF to ON at step 42, the run signal SRT remains OFF at step 43 and the sewing machine is kept stopped. When the jogging signal S4 has turned from OFF to ON at step 42, the sequence progresses to step 44, then to step 45 since a brake timer is not on. Here, the flag S4ONF for storing the ON of the jogging signal S4 is set to 1. Also, since operation is started, the run signal SRT is switched on. At step 46, it is judged whether the jogging angle has been reached or not. If it has not been reached, the process ends and the sewing machine 1 continues rotating, awaiting the next cycle through the step 40 START (not shown).
If it has been judged at step 46 that the sewing machine 1 has rotated the jogging angle, the run signal SRT is switched off at step 47, the brake signal BK is switched on at step 48, and the brake timer is set for the brake output time at step 49. The processing returns from the END at step 55 to the START at step 40. Since the flag S4ONF is now 1, the processing shifts to step 44. As the brake timer is on at step 44, the sequence moves to step 50 where the brake timer is counted up. At step 51, it is judged whether the brake timer has exceeded a given time or not. If the brake timer has not expired, the brake signal BK is switched on at step 52. If the brake timer has expired, the brake signal BK is switched off at step 53 and the flag S4ONF is cleared to 0 at step 54. The timing chart of this operation is shown in FIG. 4.
When the jogging signal S4 is switched on, the run signal SRT is switched on and the sewing machine 1 starts rotating forward because the reverse rotation signal R is 0. It is detected that the sewing machine 1 has rotated the set jogging angle (e.g., 90 degrees) using the position detection signal FG of the needle position detector 30, the run signal SRT is switched off, and the brake signal BK is switched on to stop the machine needle at a position immediately before the material. The brake signal BK is switched off in a given time. An operator moves the material at this position to determine the position of the material to be pierced with the machine needle. When the position of the material to be pierced with the machine needle has been confirmed, the operator toes down the foot pedal 10 to enter the stitching start signal S1 into the sewing machine control circuit 520, whereby the run signal SRT is output to the motor speed control circuit 13 to cause the sewing machine 1 to perform predetermined operations as in the aforementioned conventional example. When thread trimmer operation is required, the foot pedal 10 is heeled to cause the sewing machine 1 to carry out operations as in the above-mentioned conventional example to cut the machine threads. It is to be noted that the apparatus in the present embodiment, which allows the jogging angle to be set and the needle to be stopped immediately before a fabric by the motor 2, whereby the machine pulley 4 need not be rotated by hand, safety is ensured, and working efficiency is improved.
A second embodiment of the invention will now be described. The operation of the sewing machine control circuit 520, which achieves the operation of the apparatus in the present embodiment, will be described in accordance with a flowchart shown in FIG. 5. It is to be understood that the arrangement and operation of the machine controlling apparatus are identical to those of the first embodiment (Embodiment 1) with the exception of the operation of this sewing machine control circuit and will not be described.
At power-on or after thread trimming, the flag S4ONF for storing the ON of the jogging signal S4 has been cleared to 0, a reverse rotation flag RFLAG to 0, the run signal SRT to OFF, the brake signal BK to OFF, and the reverse rotation signal R to OFF.
Starting at step 40, the processing advances from step 41 to step 42 because the flag S4ONF is still 0 at step 41. Until the jogging signal S4 turns from OFF to ON at step 42, the run signal SRT remains OFF at step 43 and the sewing machine is kept stopped. When the jogging signal S4 has turned from OFF to ON at step 42, the sequence progresses to step 60. When the reverse rotation flag RFLAG is 0, the processing proceeds to step 61, where the reverse rotation signal R is set to OFF and the sewing machine rotates forward. When the reverse rotation flag RFLAG is 1 at step 60, the sequence advances to step 62, where the reverse rotation signal R is set to ON and the sewing machine rotates reversely.
Next, the processing progresses to step 44, then to step 45 since the brake timer is not on. At step 45, the flag S4ONF is set to 1. Once the jogging signal S4 is entered, it is held until the sewing machine rotates the jogging angle.
Also, since the run signal SRT is switched on at step 45, the sewing machine 1 starts rotating. At step 46, it is judged whether the sewing machine 1 has rotated the set jogging angle or not using the position detection signal FG of the needle position detector 3 of the sewing machine 1. If it has not rotated the set angle, the sewing machine 1 continues rotating. If it has rotated the set jogging angle, the run signal SRT is switched off at step 47, the brake signal BK is switched on, and the brake timer is started. Subsequently, in a next processing beginning at step 40, since the brake timer is on at step 44, the brake timer is counted up at step 50, and it is judged at step 51 whether or not the brake time has elapsed a given time. If not, the brake signal BK is kept on at step 52. If the brake time has elapsed, the brake signal BK is switched off at step 53, the flag S4ONF is set to 0 at step 54, and the sewing machine 1 comes to a stop. At this time, the reverse rotation flag RFLAG is EXCLUSIVE ORed with 1 at step 63 to invert the value. After the first forward rotation is finished, the reverse rotation flag RFLAG is set to 1.
Accordingly, when the jogging signal S4 is then entered, the reverse rotation signal R is switched on at step 62 to rotate the sewing machine 1 reversely because the reverse rotation flag RFLAG is 1 at step 60. When sewing machine has rotated the jogging angle reversely, the run signal SRT is switched off and the brake signal BK is switched on to stop the sewing machine 1. At this time, the reverse rotation flag RFLAG is set to 0.
This operation is as detailed in FIG. 6 and will not be described. It is to be noted that when the run signal SRT is used for stitching in the forward direction with the machine needle stopping immediately before the material, the distance of piercing the material is short, the speed is not high enough when the material is pierced, and the force of inertia is small, whereby torque required to pierce the material is not provided and the sewing machine stops. However, the apparatus in the present embodiment allows the sewing machine to rotate by the jogging angle once to move the machine needle away from the material under the control of the jogging signal entered again and subsequently to rotate forward under the control of the run signal SRT, whereby the distance of piercing the material is large, the speed of piercing the material is high, and the force of inertia is therefore large to facilitate the piercing of the material.
A third embodiment of the invention will now be described. In the sewing machine controlling apparatus described in Embodiment 2, further entry of the jogging signal S4 causes the sewing machine 1 to rotate forward since the reverse rotation flag RFLAG is 0. After the sewing machine 1 has stopped, the reverse rotation flag RFLAG is inverted to 1. When the jogging signal S4 is further entered, the sewing machine 1 rotates reversely because the RFLAG is 1. Accordingly, every time the jogging signal S4 is entered, the sewing machine 1 alternates between forward rotation and reverse rotation. The timing chart of this operation is shown in FIG. 7. It is to be noted that the present embodiment allows the position where the material is pierced with the machine needle to be re-adjusted to improve working efficiency.
A fourth embodiment of the invention will now be described. Operation performed at the application of the stitching start signal S1 will be described with reference to FIG. 8. When a flag S1F, which stores the ON of the stitching start signal S1, is 0 at step 70, the processing moves on to step 71 once. If the stitching start signal S1 is off at step 71, the processing advances to step 41, where the operation as in Embodiment 3 shown in FIG. 7 is performed. When the stitching start signal S1 has turned from OFF to ON at step 71, the sequence progresses to step 72, where the run signal SRT is switched on and the flag S1F is set to 1. At step 73, it is judged whether the reverse rotation flag RFLAG is 1 or not. If it is 1, the reverse rotation signal R is set to ON at step 74 and the sewing machine 1 rotates reversely. If the reverse rotation flag RFLAG is 0 at step 73, the sewing machine 1 rotates forward, not reversely. At step 75, it is judged whether the sewing machine 1 has rotated the set jogging angle in the reverse direction. If the jogging angle has not been reached, the sequence advances to step 77. If the set jogging angle has been reached, the reverse rotation flag RFLAG is set to 0 and the reverse rotation signal R is switched off to run the sewing machine 1 forward. At step 77, it is monitored whether or not the stitching start signal S1 has turned from ON to OFF. If it has changed from ON to OFF, stop processing is performed at step 78. If it has been judged at step 79 that the stop processing is complete, the flag S1F is set to 0 at step 69.
Accordingly, when the stitching start signal S1 is switched on with the sewing machine 1 stopping at the position of 90 degrees after rotating by the jogging angle forward under the control of the jogging signal S4, the sewing machine 1 is rotated reversely by the jogging angle, then rotates forward and stitches the material. Therefore, when the stitching start signal S1 is applied with the needle stopping immediately before the material, the sewing machine 1 rotates reversely once and then operates, thereby eliminating a problem that the sewing machine 1 stops without piercing the material.
When the machine needle is at a stop at the needle UP position, i.e., 0 degrees, because the jogging signal S4 has not been provided or an even number of jogging signals S4 have been entered, the sewing machine 1 does not rotate reversely but rotates forward once since the reverse rotation flag RFLAG is 0, whereby extra reverse rotation is not made and working efficiency is high. The timing chart of this operation is shown in FIG. 9.
A fifth embodiment of the invention will now be described. The operation of the sewing machine control circuit 520 concerned with the present embodiment will be described with reference to a flowchart in FIG. 10. When the flag S1F, which stores the ON of the stitching start signal S1, is 0 at step 70, the processing proceeds to step 71. It is judged at step 71 whether or not the stitching start signal S1 has turned from OFF to ON. If it has turned from OFF to ON, the processing advances to step 80. When a delay timer is not on, the sequence progresses to step 72, where the run signal SRT is switched on and the flag S1F is set to 1.
At step 73, it is judged whether the reverse rotation flag RFLAG is 1 or not. If it is 1, the processing moves on to step 74, where the reverse rotation signal R is switched on to rotate the sewing machine reversely. If the reverse rotation flag RFLAG is 0, the reverse rotation flag R is switched off to run the sewing machine 1 forward. At step 75, it is judged whether the sewing machine 1 has rotated the set jogging angle. If the jogging angle has not been reached, the sewing machine continues reverse rotation. If the sewing machine has made the reverse rotation of the set jogging angle, the run signal SRT is switched off, the brake signal BK is switched on, the reverse rotation flag RFLAG is cleared to 0, and the brake timer and the delay timer, which sets a short stop time, are started.
Next, since the delay timer is on at step 80, the run signal SRT is switched off at step 83 and the delay timer is counted up at step 84. At step 85, it is judged whether or not the delay timer has been counted up. If not, the processing advances to step 86. If the delay time has elapsed, the sequence progresses to step 72, where operation is started. Since the reverse rotation flag RFLAG is 0 at step 73, the sequence moves on to step 81, where the reverse rotation signal R is switched off to make a forward rotation. The brake timer is counted up at step 86 and it is judged at step 87 whether the brake time has elapsed or not. If not, the brake signal BK is switched on and the reverse rotation signal R is also switched on at step 88 and the sewing machine is at a stop. After the brake time has elapsed, the brake signal BK is switched off and the reverse rotation signal R is also switched off at step 89. Then, since the delay timer has expired, the processing advances from step 80 to step 72, where the sewing machine 1 performs forward rotation.
Accordingly, after making reverse rotation under the control of the stitching start signal S1, the sewing machine stops once, then rotates forward. The timing chart of this operation is shown in FIG. 11. According to the present embodiment, the sewing machine does not shift directly from reverse rotation to forward rotation, preventing the occurrence of skip stitches, etc., due to the unevenly fed machine thread.
A sixth embodiment of the invention will now be described. FIG. 12 shows operation wherein the jogging signal S4 has not been provided in the sewing machine controlling method described in Embodiment 5. When the stitching start signal S1 is entered, the run signal SRT is switched on and forward rotation is performed because the reverse rotation signal R is off. The reason is that since the inversion of the reverse rotation flag RFLAG at step 63 in FIG. 10 is not made when the jogging signal S4 is not given, the reverse rotation signal RFLAG is 0, whereby the reverse rotation flag RFLAG is judged to be 0 at step 73 and the reverse rotation signal R is switched off at step 81 to start the sewing machine running in the forward direction and therefore working efficiency is improved.
A seventh embodiment of the invention will now be described. FIG. 13 shows that operation starts with forward rotation whenever the jogging signal S4 is entered after the sewing machine 1 has run under the control of the stitching start signal S1 in the sewing machine controlling method described in Embodiment 5. Switching on the jogging signal S4 rotates the sewing machine in the forward direction, independently of whether the sewing machine 1 has jogged in the forward direction or in the reverse direction before the stitching start signal S1 was entered. The reason is that since the reverse rotation flag RFLAG is cleared at step 82 at the input time of the stitching start signal S1, the reverse rotation flag RFLAG is 0 at step 60 when the next jogging signal S4 is switched on, and therefore the reverse rotation signal R is switched off at step 61.
When the jogging signal S4 is entered, the apparatus according to this embodiment always rotates the jogging angle in the forward direction, improving working efficiency.
An eighth embodiment of the invention will now be described. FIG. 14 is an arrangement diagram of a sewing machine controlling apparatus concerned with the present embodiment, wherein 32 indicates a reverse rotation angle setting circuit serving as reverse rotation angle setting means, S5 designates a reverse rotation signal, and 521 represents a sewing machine control circuit detailed in FIG. 16. When a material 98 as shown in FIG. 15 is to be stitched by a blind stitching machine, for example, start backtacking is done at portion 90 and first straight stitching is made at portion 91 under the control of the stitching start signal S1. When the stitching start signal S1 is switched off, the sewing machine stops at the needle DOWN position once at portion 92, but the blind stitching machine does not allow the direction of the material to be changed unless reverse-rotation needle UP is carried out. Accordingly, the reverse rotation signal S5 is switched on at portion 92 to perform reverse-rotation needle UP. It is to be understood that reverse-rotation needle UP indicates that the machine needle is raised in the reverse rotation.
Likewise, second, third and fourth straight stitchings are done at portions 93, 95 and 97, respectively. As at portion 92, the reverse-rotation needle UP is performed at portions 94 and 96 to change the direction of the material. Under the control of the thread trimmer start signal S2, end backtacking is carried out at portion 99, which is followed by reverse-rotation needle UP at portion 200 because the material 98 cannot be removed from the sewing machine 1 without doing the reverse-rotation needle UP. Therefore, reverse-rotation needle UP is performed by the reverse rotation signal S5, and end backtacking and reverse-rotation needle UP are done by the jogging signal.
The operation of the sewing machine control circuit 521 will now be described in accordance with a block diagram in FIG. 16. When the reverse rotation signal S5 is switched on, the run control circuit 310 switches the run signal SRT on and the reverse rotation signal R on via the run signal input circuit 301 to start the motor 1 reversing.
At this time, the reverse rotation angle set to the reverse rotation angle setting circuit 32 is compared by the angle comparison circuit 311 with the rotary angle of the sewing machine 1 entered into the needle position input circuit 312 from the needle position detection signal FG given by the needle position detector 3. When the sewing machine 1 has rotated the set reverse rotation angle or more in the reverse direction, the run control circuit 310 causes the rotation/stop command circuit 305 to switch the run signal SRT off and the brake signal BK on to stop the sewing machine 1.
FIG. 17 is a software flowchart for said reverse rotation needle UP. In FIG. 17, S5ONF indicates a flag which stores that the reverse rotation signal S5 has been switched on once. At step 100, it is judged whether the flag S5ONF is 1 or 0. If it is 0, the processing goes forward to step 101. If the reverse rotation signal S5 does not turn from OFF to ON, the run signal SRT is switched off at step 43 to stop the sewing machine 1. When the reverse rotation signal S5 has turned from OFF to ON at step 101, the sequence advances to step 44. When the brake timer is not on, the sequence proceeds to step 102, where the flag S5ONF is set to 1, the reverse rotation signal R is switched on and the run signal SRT is switched on to rotate the sewing machine 1 reversely. At step 46, it is judged whether or not the sewing machine 1 has reversed the set reverse rotation angle. If not, the sewing machine 1 performs reverse rotation. If the sewing machine 1 has reversed the set reverse rotation angle, the processing progresses to step 47, where the run SRT signal is switched off and the brake signal BK is switched on. At step 49, the brake timer is started.
Since the brake timer is on at step 44, the sequence moves on to step 50, where the brake timer is counted up. At step 51, it is judged whether or not the brake time has elapsed. If not, the brake signal BK is switched on at step 52. If the brake time has elapsed, the brake signal BK is switched off at step 53, the flag S5ONF is set to 0 at step 103, and the reverse rotation signal R is switched off at step 104. As a result, the reverse rotation signal S5 causes the sewing machine 1 to reverse the set reverse rotation angle and come to a stop. This timing chart is shown in FIG. 18. After the sewing machine 1 has reversed the reverse rotation angle set to the reverse rotation angle setting circuit 32, the operator toes down the foot pedal 10 to enter the stitching start signal S1 into the sewing machine control circuit 520, and as in said conventional example, the run signal SRT is output to the motor speed control circuit 13 and the sewing machine 1 performs predetermined operation. When thread trimmer operation is required, heeling the foot pedal 10 causes the sewing machine 1 to perform the operation as in said conventional example to cut the machine threads. The apparatus in the present embodiment allows the reverse-rotation needle UP operation to be performed when the direction of the material is changed on the blind stitching machine, improving working efficiency.
A ninth embodiment of the invention will now be described. FIG. 19 is a software flowchart of the sewing machine control circuit 521 concerned with Embodiment 9. This mainly represents the processing performed at portions 99 and 200 in FIG. 15. At step 110, it is judged whether the sewing machine 1 is being run or not. If the sewing machine 1 is being run, operation by the reverse rotation signal S5 is not performed. If the sewing machine 1 is at a stop, the processing proceeds to step 111, where it is judged whether or not the sewing machine 1 is at a stop after it has run once. If not, the sequence advances to step 118, where reverse rotation needle UP processing is performed when the reverse rotation signal S2 is entered. If the sewing machine 1 is at a stop after it has run once, the processing progresses to step 100. If the flag S2ONF, which stores that the reverse rotation signal S5 has switched on once, is 1, the processing moves on to step 113. If the flag S2ONF is 0, the sequence moves forward to step 101. When the reverse rotation signal S5 has not turned from OFF to ON, the processing advances to step 118. When the reverse rotation signal S5 has turned from OFF to ON, the flag S2ONF is set to 1 at step 112. At step 113, it is judged whether or not end backtacking has finished. If not, the sequence proceeds to step 114, where end backtacking processing is done. If end backtacking has ended at step 113, the sequence advances to step 115, where it is judged whether or not reverse rotation needle UP has ended. If not, reverse rotation needle UP is performed. It reverse rotation needle UP has finished, the flag S2ONF is set to 0.
As described above, when the reverse rotation signal S5 is on, end backtacking is done, reverse rotation needle UP follows, and after a stop, the material can be removed. FIG. 20 shows the timing chart of the above operation. The apparatus in the present embodiment allows either the reverse-rotation needle UP or the end backtacking and reverse-rotation needle UP to be done, improving working efficiency.
A tenth embodiment of the invention will now be described. FIG. 21 shows a sewing machine controlling apparatus concerned with the present embodiment which operates under the control of a second needle UP signal. Unlike the needle UP signal S3 in said conventional apparatus, this second needle UP signal raises the machine needle from its then position independently of the rotation direction of the machine needle and will be described later in detail. In this drawing, 522 indicates a sewing machine control circuit detailed in FIG. 22 and S6 is a second needle UP signal. The other parts are identical to those in the conventional apparatus shown in FIG. 64 and will not be described. It is to be noted that the sewing machine control circuit 522 is different in operation sequence of the run control circuit 320 from the one in the conventional example in FIG. 64.
FIG. 23 is a software flowchart of the sewing machine control circuit 522, wherein S6ONF is a flag which stores whether or not the second needle UP signal S6 has turned on once. If the flag S6ONF is 0 at step 120, the processing advances to step 121. When the second needle UP signal S6 has turned from OFF to ON, the sequence proceeds to step 122, where it is judged whether or not the needle UP signal UP is on. If not on, the run signal SRT is switched on at step 123 and the flag S6ONF is set to 1 at step 124. When the machine needle is in a range from the UP position to the DOWN position in the forward rotation direction, i.e., in area A in FIG. 24, at step 125, the reverse rotation signal R is switched on at step 126. When the machine needle is in a range from the DOWN position to the UP position in the forward rotation direction, i.e., in area B in FIG. 24, the reverse rotation signal R is switched off at step 127. Since the flag S6ONF is 1 at step 124, the sequence then moves to step 44 at step 120. Since the brake timer is not on, the processing progresses to step 128, where the sewing machine rotates under the control of the reverse rotation signal R set at step 126 or 127 until the UP position signal UP is switched on.
FIG. 25 is a timing chart at a time when the machine needle is in the range from the UP position to the DOWN position in the forward rotation direction. Namely, when the machine needle is in area A in FIG. 24, the reverse rotation signal R is switched on at step 126, whereby the machine needle is rotated in the reverse direction and stops at the UP position. FIG. 26 is a timing chart at a time when the machine needle is in the range from the DOWN position to the UP position in the forward rotation direction. Namely, when the machine needle is in area B in FIG. 24, the reverse rotation signal R is switched off at step 127, whereby the machine needle is rotated in the forward direction and stops at the UP position. When stitching, for example, is started after the machine needle has stopped at the UP position, the operator toes down the foot pedal 10 to enter the stitching start signal S1 into the sewing machine control circuit 520, and as in said conventional example, the run signal SRT is output to the motor speed control circuit 13 and the sewing machine 1 performs predetermined operation. When thread trimmer operation is required, heeling the foot pedal 10 causes the sewing machine 1 to perform the operation as in the conventional example to cut the machine threads. The apparatus in the present embodiment allows reverse rotation needle UP to be performed before the material is pierced with the machine needle and forward rotation needle UP to be performed after the material is pierced with the machine needle, thereby preventing the material from being seamed or bored.
An eleventh embodiment of the invention will now be described. FIG. 27 is a software flowchart of the sewing machine control circuit 522 concerned with Embodiment 11, wherein a flag PONF which indicates whether or not needle is in the up position immediately after power-on is initialized to 0, at power-on. Since the flag PONF is initially 0 at step 130 the processing progresses to step 122, where if the needle UP position signal UP is on, the flag PONF is set to 1 at step 131, whereby needle UP processing is not performed and is regarded as complete.
When the needle is not in the UP position at step 122, the run signal SRT is switched on at step 123 and the flag S6ONF is set to 1. If the machine needle is in the range from the UP position to the DOWN position in the forward rotation direction at step 125, the reverse rotation signal R is switched on at step 126 to raise the needle in the reverse rotation direction. When the machine needle is in the range from the DOWN position to the UP position in the forward rotation direction, the reverse rotation signal R is switched off at step 127 to raise the needle in the forward rotation direction. After needle UP processing is finished, the flag PONF is set to 1 at step 132 and it is stored that the needle UP immediately after power-on is complete to accept only needle UP performed under the control of the second needle UP signal S6 thereafter.
The apparatus in the present embodiment prevents the material from being seamed or bored at power-on.
An embodiment of a twelfth invention will now be described. FIG. 28 is a software flowchart of the sewing machine control circuit 522 concerned with Embodiment 12, wherein it is judged at step 140 whether or not the sewing machine 1 has stopped after thread trimming, and the jogging signal S4 is made valid only when the sewing machine has stopped after thread trimming. The other parts are identical to those of Embodiment 1described in FIG. 3. According to the apparatus in this embodiment, when the machine needle need not be stopped immediately before the material, the machine needle does not rotate if the jogging signal S4 switch is touched accidentally, whereby the sewing machine is not jogged carelessly.
An embodiment of a thirteenth invention will now be described. FIG. 29 is an arrangement diagram of a sewing machine controlling apparatus concerned with the present embodiment, wherein 523 indicates a sewing machine control circuit which is detailed in FIG. 30. Referring to FIGS. 29 and 30, switching the stitching start signal S1 on causes the run control circuit 340 to switch the run signal SRT on and the reverse rotation signal R on via the run signal input circuit 301 to start the motor 2 running in the reverse direction. At this time, the reverse rotation angle set to the reverse rotation angle setting circuit 32 is compared by the angle comparison circuit 311 with the rotary angle of the sewing machine 1 provided by entering the position detection signal FG from the needle position detector 3 into the needle position input circuit 312. When the sewing machine has rotated the set reverse rotation angle or more in the reverse direction, the run control circuit 340 causes the rotation/stop command circuit 305 to switch the reverse rotation signal R off to switch the motor 2 to the forward rotation.
FIG. 31 is a timing chart of the above operation, wherein the machine needle is at a stop at 40 degrees, i.e., at the thread take-up lever top dead center. When the stitching start signal S1 is switched on at this time, the run signal SRT is switched on to start the sewing machine 1 running. At this time, the reverse rotation signal R is switched on and the sewing machine 1 makes the reverse rotation of the reverse rotation angle (e.g., 90 degrees) set to the reverse rotation angle setting circuit 32 at predetermined speed.
After the sewing machine 1 has reversed the set angle, the reverse rotation signal R is switched off and the sewing machine 1 rotates in the forward direction. The forward rotation speed at this time corresponds to the speed command signal VC proportional to the toe-down degree of the pedal 10.
FIG. 32 is a software flowchart of a sewing machine control circuit 523 concerned with Embodiment 13. When the sewing machine 1 is at a stop, a run flag S1F is 0. Beginning with START at step 38, the processing of this routine is started. At step 39, the reverse rotation angle is read from the reverse rotation angle setting circuit 32. If the sewing machine is at a stop at step 40, the sequence advances to step 41 since the run flag S1F is 0. At step 41, the processing waits for the stitching start signal S1 to be switched on. If it is not switched on, the reverse rotation flag RFLAG is set to 1 at step 42. When the stitching start signal S1 is switched on at step 41, the sequence proceeds to step 43. It is judged at step 43 whether or not the machine needle is at a stop at the UP position. If it is not at the UP position, the processing progresses to step 54, where the reverse rotation flag RFLAG is cleared to 0. Since the run signal SRT is switched on at step 44, the sewing machine 1 starts rotating. The run FLAG S1F is also set to 1.
Since the reverse rotation flag RFLAG is 0 at step 45, the reverse rotation signal R is switched off at step 48, whereby the sewing machine rotates in the forward direction, not in the reverse direction.
When the machine needle is at a stop a the UP position at step 43, the reverse rotation flag RFLAG is 1 at step 45, the processing moves on to step 46, where the reverse rotation signal R is switched on to rotate the sewing machine in the reverse direction. At step 47, it is judged whether the sewing machine has reversed the set reverse rotation angle or not. Until the sewing machine 1 reverses the set reverse rotation angle, the processing advances to step 49, where the sewing machine continues reverse rotation.
When the sewing machine has reversed the set reverse rotation angle at step 47, the sequence proceeds to step 48, where the reverse rotation flag RFLAG is set to 0 and the reverse rotation signal R is switched off, whereby the sewing machine 1 that was rotating in the reverse direction changes the direction to rotate in the forward direction. If the stitching start signal S1 remains on at step 49, the sewing machine 1 continues operation.
When the stitching start signal S1 is switched off at step 49, stop processing is performed at step 50, the sewing machine 1 rotates until it reaches the needle UP or DOWN position, and the sewing machine 1 reaches the needle position at step 51. When the stop processing ends, the run signal SRT is switched off and the run flag S1F is reset to 0 at step 52 to stop the sewing machine 1. This routine ends at step 53 and starts at step 38 again.
According to the apparatus of this embodiment, when the sewing machine 1 is at a stop at the needle UP position or after it has trimmed the threads, the sewing machine 1 reverses the set reverse rotation angle and then rotates in the forward direction, whereby the speed of piercing the material can be increased.
A fourteenth embodiment of the invention will now be described. An arrangement diagram concerned with a sewing machine controlling apparatus of Embodiment 14 is identical to the one in FIGS. 29 and 30 described in said Embodiment 13 and will not be described.
FIG. 33 is a software flowchart of the sewing machine controlling apparatus concerned with Embodiment 14. In this drawing, while the sewing machine 1 is at a stop, the run flag S1F is 0. Beginning with START at step 38, the processing of this routine is started. At step 39, the reverse rotation angle is read from the reverse rotation angle setting circuit 32.
If the sewing machine is at a stop at step 40, the sequence advances to step 41 since the run flag S1F is 0. At step 41, the processing waits for the stitching start signal S1 to be switched on. If it is not switched on, the reverse rotation flag RFLAG is set to 1 at step 42.
When the stitching start signal S1 is switched on at step 41, the sequence proceeds to step 60.
It is judged at step 60 whether the sewing machine has trimmed the threads or not. If not, the processing progresses to step 54, where the reverse rotation flag RFLAG is cleared to 0. Since the run signal SRT is switched on at step 44, the sewing machine 1 starts rotating. The run flag S1F is also set to 1. The reverse rotation flag RFLAG is 0 at step 45 and the reverse rotation signal R is switched off at step 48, whereby the sewing machine 1 rotates in the forward direction, not in the reverse direction.
When the machine needle is at a stop at the UP position, the reverse rotation flag RFLAG is 1 at step 45, and the processing moves on to step 46, where the reverse rotation signal R is switched on to rotate the sewing machine 1 in the reverse direction.
At step 47, it is judged whether the sewing machine has reversed the set reverse rotation angle or not. Until the sewing machine 1 reverses the set reverse rotation angle, the processing advances to step 49, where the sewing machine 1 continues reverse rotation.
When the sewing machine has reversed the set reverse rotation angle at step 47, the sequence proceeds to step 48, where the reverse rotation flag RFLAG is set to 0 and the reverse rotation signal R is switched off, whereby the sewing machine 1 that was rotating in the reverse direction changes the direction to rotate in the forward direction.
If the stitching start signal S1 remains on at step 49, the sewing machine 1 continues operation. When the stitching start signal S1 is switched off at step 49, stop processing is performed at step 50, the sewing machine 1 rotates until the machine needle reaches the UP or DOWN position, and the sewing machine 1 reaches the needle UP or DOWN position at step 51. When the stop processing ends, the run signal SRT is switched off and the run flag S1F is reset to 0 at step 52 to stop the sewing machine 1. This routine ends at step 53 and restarts at step 38. The apparatus of this embodiment allows the machine needle to stop immediately before the material, whereby the machine pulley 4 need not be rotated by hand.
A fifteenth embodiment of the invention will now be described. FIG. 34 is an arrangement diagram of a sewing machine controlling apparatus concerned with this embodiment, wherein 524 indicates a sewing machine control circuit detailed in FIG. 35 and S4 denotes a jogging signal. It is to be understood that the other parts are identical to those of Embodiment 1shown in FIG. 1 and will not be described.
The operation of the sewing machine control circuit 524 will be described in accordance with a block diagram shown in FIG. 35. When the jogging signal S4 is switched on, the run control circuit 350 causes the run signal SRT to be switched on via the run signal input circuit 301, the sewing machine 1 to start rotating, and the thread trimmer output T to be output from the solenoid control circuit 303.
Starting at a point when the sewing machine 1 has detected the needle UP position signal UP of the needle position detector 3 from the needle UP/DOWN position input circuit 302, the jogging angle (e.g., 35 degrees) set to the angle setting circuit 30 is compared by the angle comparison circuit 311 with the rotary angle of the sewing machine 1 entered from the position detection signal FG given by the needle position detector 3 via the needle position input circuit 312. When the sewing machine 1 has reached or exceeded the set jogging angle, the run control circuit 350 causes the rotation/stop command circuit 305 to switch the run signal SRT off and the brake signal BK on to stop the sewing machine 1 at the set jogging angle.
Operation will now be described in accordance with a timing chart in FIG. 36. When the jogging signal S4 is switched on, the run signal SRT is output to start the sewing machine 1 rotating and the thread trimmer output T is output to cut the threads. When the needle UP position signal UP is switched on, the thread trimmer output T is switched off and a jogging command flag S4ONF is set to 1 to start jogging. When the sewing machine 1 has rotated the set jogging angle, the run signal SRT is switched off and the brake signal BK is output for a certain period of time to stop the sewing machine 1, and the jogging command flag S4ONF is set to 0.
Accordingly, after thread trimming, the machine needle automatically rotates the jogging angle set to the jogging angle setting circuit 30 in the forward direction, starting at the needle UP position, and comes to a stop.
When, after the stop, the presser foot is raised, the material sewn is removed, and the material to be stitched next is inserted, where to start stitching the next materials made clear because the machine needle is immediately before the material.
Operation will now be described in accordance with a flowchart in FIG. 37. Beginning with step 60, it is judged at step 61 whether or not the sewing machine 1 has operated once. If not, no processing is performed at END of step 79 and the sequence is finished. If it has been judged at step 61 that the sewing machine 1 has operated once, the sequence advances to step 62. If a thread trimmer flag TRIMF is 1, the sequence proceeds to step 64. If the thread trimmer flag TRIMF is 0 at step 62, the sequence progresses to step 63, where it is judged whether or not the jogging signal S4 is on. If it is off, no operation is performed and the sequence moves on to END of step 79. If the jogging signal S4 is on, the sequence proceeds to step 64, where the thread trimmer flag TRIMF is set to 1.
At step 65, where thread trimmer processing is carried out, the thread trimmer output T is provided and the sewing machine 1 is rotated up to the needle UP position. At step 66, it is judged whether or not the machine needle has reached the UP position. If not, the thread trimmer processing is continued. If the machine needle has reached the UP position once, the sequence advances to step 67. If the brake timer is not on, the sequence proceeds to step 68, where the flag S4ONF for storing that jogging processing has initiated is set to 1.
Also, the run signal SRT is switched on to start the operation of the sewing machine 1. At step 69, it is judged whether or not the jogging angle has been reached. If not, the sewing machine keeps rotating.
If it has been judged at step 69 that the jogging angle has been rotated, the run signal SRT is switched off at step 70, the brake signal BK is switched on at step 71, and the brake timer is set for the brake output time at step 72. The sequence returns from END of step 79 to START of step 60 and shifts to step 64 since the thread trimmer flag TRIMF is now 1. Because the machine needle has reached the UP position once at step 66, the processing shifts to step 67. Since the brake timer is on at step 67, the processing shifts to step 73, where the brake timer is counted up. At step 74, it is judged whether or not the brake timer has exceeded the given time. If the brake timer has not expired, the brake signal BK is switched on at step 75. If the brake timer has expired, the brake signal BK is switched off at step 76, the flag S4ONF is cleared to 0 at step 77, and the thread trimmer flag TRIMF is cleared to 0 at step 78. It is to be understood that stitching start or thread trimmer start is made as described in said conventional example and will not be described here.
A sixteenth embodiment of the invention and a seventeenth embodiment of the invention will now be described. The arrangement of an apparatus in the present embodiment is identical to that in Embodiment 15and will not be described. FIG. 38 illustrates the operation of a sewing machine controlling apparatus concerned with Embodiment 16, showing the operation which begins with a stop at the needle UP position after thread trimming.
When the jogging signal S4 is switched on in this status, the run signal SRT is switched on and the reverse rotation signal R is on the forward rotation side, whereby the sewing machine 1 starts forward rotation. Since the jogging command flag S4ONF is 1 at this time, the sewing machine 1 rotates by the jogging angle set in the jogging angle setting circuit 30 (e.g., 35 degrees) in the forward direction, whereby the run signal SRT is switched off, the reverse rotation flag RFLAG is inverted to 1, and the brake signal BK is switched on to stop the machine needle at a position immediately before the material. The operator moves the material at this position to set the position of the material to be pierced with the machine needle.
Further, when the jogging signal S4 is switched on again, the run signal SRT is switched on, the reverse rotation signal R is set to the reverse rotation side because the reverse rotation flag RFLAG is 1, and the sewing machine 1 starts reverse rotation. Since the jogging command flag S4ONF is 1 at this time, rotating the sewing machine 1 by the angle set to the jogging angle setting circuit 30 (90 degrees in the figure) in the reverse direction causes the run signal SRT to be switched off, the reverse rotation flag RFLAG to be inverted to 0, and the brake signal BK to be switched on, whereby the sewing machine 1 is reversed to the needle UP position and brought to a stop.
When the material is stitched in the forward rotation under the control of the stitching start signal S1 after the machine needle has been stopped immediately before the material, the distance of piercing the material is short and the speed of piercing the material is not high enough to provide the sufficient force of inertia, whereby the torque required to pierce the material is not provided and the sewing machine 1 comes to a stop. To prevent this, if the jogging signal S4 is switched on again to rotate the machine needle by the jogging angle to move away from the material once and subsequently the needle is rotated in the forward direction under the control of the stitching start signal S1, the distance of piercing the material is increased and the speed of piercing the material is increased to provide larger force of inertia, whereby the material can be pierced.
The sewing machine control circuit 524 which has achieved this operation will now be described in accordance with a flowchart in FIG. 39.
At power-on or after thread trimming, the flag S4ONF for storing that the jogging processing has started is initialized to 0, the reverse rotation flag RFLAG to 0, the run signal SRT to OFF, the brake signal BK to OFF, and the reverse rotation signal R to OFF.
Starting at step 80, it is judged at step 81 whether the sewing machine 1 has done thread trimming or not. If not, the sequence proceeds to step 103. If the sewing machine 1 has already done thread trimming, the sequence progresses to step 83 because the S4ONF is still 0 at step 82. Until the jogging signal S4 turns from OFF to ON at step 83, the run signal SRT is OFF at step 84, whereby the sewing machine 1 remains stopped. If the jogging signal S4 is on at step 85, presser foot UP processing is performed at step 86. If the jogging signal S4 is off at step 85, presser foot DOWN processing is performed at step 87. If the jogging signal S4 has turned from OFF to ON at step 83, the sequence proceeds to step 88. If the reverse rotation flag RFLAG is 0, the sequence advances to step 89, where the reverse rotation signal R is set to OFF, whereby the sewing machine 1 rotates in the forward direction. If the reverse rotation flag RFLAG is 1 at step 88, the sequence moves on to step 90, where the reverse rotation signal R is set to ON, whereby the sewing machine 1 rotates in the reverse direction.
Next, the processing advances to step 91. Since the brake timer is not on, the processing moves forward to step 92, where the flag S4ONF is set to 1, and once the jogging signal S4 is entered, it is held until the sewing machine 1 finishes the rotation of the jogging angle.
Since the run signal SRT is set to ON at step 92, the sewing machine 1 starts rotating. At step 93, it is judged whether or not the sewing machine 1 has rotated the set jogging angle using the position detection signal FG of the needle position detector 3 of the sewing machine 1. If not, the sewing machine keeps rotating. If it has rotated the set jogging angle, the run signal SRT is switched off at step 94, the brake signal BK is switched on, and the brake timer is started. Thereafter, since the brake timer is on at step 91, the brake timer is counted up at step 97 and it is judged at step 98 whether the given brake time has elapsed or not. If not, the brake signal BK is kept on at step 99. After the brake time has elapsed, the brake signal BK is switched off at step 100, the flag S4ONF is set to 0 at step 101, and the sewing machine 1 stops. At this time, the reverse rotation flag RFLAG is EXCLUSIVE ORed with 1 to invert the value. After the first forward rotation is over, the reverse rotation flag RFLAG is set to 1.
Accordingly, when the jogging signal S4 is entered next, the reverse rotation flag RFLAG is 1 at step 88, whereby the reverse rotation signal R is switched on at step 90 to run the sewing machine 1 in the reverse direction. When the sewing machine 1 has reversed by the jogging angle, the run signal SRT is switched off and the brake signal BK is switched on to stop the sewing machine 1. At this time, the reverse rotation flag RFLAG is set to 0.
When the jogging signal S4 is further entered, the sewing machine 1 rotates forward because the reverse rotation flag RFLAG is 0. After a stop, the reverse rotation flag RFLAG is inverted to 1. When the jogging signal S4 is further entered, the sewing machine 1 rotates reversely because the reverse rotation flag RFLAG is 1. Therefore, every time the jogging signal S4 is entered, the sewing machine 1 alternates between forward rotation and reverse rotation. This allows the position where the material is pierced with the machine needle to be readjusted.
At step 103, it is judged whether the jogging signal S4 has been entered or not. If not, the sequence is terminated at END of step 105 with no further operation being performed. If the jogging signal S4 has been entered, thread trimmer processing is performed.
An eighteenth embodiment of the invention will now be described. The arrangement of the apparatus in this embodiment is identical to that of said Embodiment 16and will not be described.
Assuming that the jogging angle of 35 degrees, for example, has been set to the jogging angle setting circuit 30 in FIG. 34, operation will be described in accordance with a timing chart in FIG. 40. It is to be understood that switching the thread trimmer start signal S2 on causes the run signal SRT to be output, the sewing machine 1 to start rotating, and the thread trimmer output T to be provided to cut the threads. When the needle UP position signal UP is switched on, the thread trimmer output T is switched off, the run signal SRT is switched off, the brake signal BK is output for a given length of time, and a wiper output W for thread wiping is provided for a predetermined period of time. When the brake signal BK is switched off in a given period of time, the run signal SRT is switched on and the jogging command flag S4ONF is set to 1 to start jogging. When the sewing machine has rotated by the set jogging angle, the run signal SRT is switched off and the brake signal BK is output for a predetermined length of time to make a stop, and the jogging command flag S4ONF is set to 0.
Accordingly, after thread trimming, the sewing machine 1 stops for a given time and performs wiper operation, and the machine needle automatically rotates the jogging angle set to the jogging angle setting circuit 30 in the forward direction, starting at the needle UP position, and comes to a stop.
When, after the stop, the presser foot is raised, the material sewn is removed, and the material to be stitched next is inserted, where to start stitching the material next is made clear because the machine needle is immediately before the material.
Operation will now be described in accordance with a flowchart in FIG. 41. Beginning with step 60, it is judged at step 61 whether the sewing machine 1 has operated once. If not, no processing is performed at END of step 79 and the sequence is finished.
If it has been judged at step 61 that the sewing machine 1 has operated once, the sequence advances to step 62. If the thread trimmer flag TRIMF is 1, the sequence proceeds to step 64. If the thread trimmer flag TRIMF is 0 at step 62, the sequence progresses to step 63, where it is judged whether or not the thread trimmer start signal S2 is on. If it is off, no operation is performed and the sequence moves on to END of step 79.
If the thread trimmer start signal S2 is on, the sequence proceeds to step 64, where the thread trimmer flag TRIMF is set to 1. At step 65, thread trimmer processing is carried out, the thread trimmer output T is provided, and the sewing machine 1 is rotated up to the needle UP position. At step 66, it is judged whether or not the machine needle has reached the UP position. If not, the thread trimmer processing is continued.
If it has been judged at step 66 that the machine needle has reached the UP position once, the sequence advances to step 400, where it is judged whether or not the brake timer is on the first time. If so, the sequence proceeds to step 401, where it is judged whether the wiper is on or not. If the wiper is on, the processing progresses to step 402, where the wiper output W is switched on. If the wiper is not on, the sequence proceeds to step 403, where the wiper output is switched off and the processing moves on to step 73. When the first brake time has ended, the sequence progresses to step 67. If the brake timer is not on the second time, the sequence proceeds to step 68. Here, a flag S01ONF for storing that the jogging processing has initiated is set to 1.
Also, the run signal SRT is switched on to start the sewing machine 1 running. At step 69, it is judged whether or not the jogging angle has been reached. If not, the sewing machine 1 keeps rotating.
If it has been judged at step 69 that the jogging angle has been rotated, the run signal SRT is switched off at step 70, the brake signal BK is switched on at step 71, and the brake timer is set for the brake output time at step 72. The sequence returns from END of step 79 to START of step 60 and shifts to step 64 since the thread trimmer flag TRIMF is 1 at this time. Because the machine needle has reached the UP position once at step 66, the processing shifts to step 67. Since the brake timer is on at step 67, the processing shifts to step 73, where the brake timer is counted up. At step 74, it is judged whether or not the brake timer has exceeded the given time. If the brake timer has not expired, the brake signal BK is switched on at step 75. If the brake timer has expired, the brake signal BK is switched off at step 76, the flag S4ONF is cleared to 0 at step 77, and the thread trimmer flag TRIMF is cleared to 0 at step 78. According to the apparatus in the present embodiment, the wiper, if any, makes contact with the machine needle when the thread is wiped by the wiper after the machine needle has stopped immediately before the material, and to prevent this, the sewing machine 1 is stopped once at the needle UP position, the wiper is operated, and the sewing machine 1 is rotated by the jogging angle again to stop the machine needle at the position immediately before the material, whereby the wiper does not come into contact with the machine needle and the needle fall position for the next material can be adjusted easily.
A nineteenth embodiment of the invention will now be described. FIG. 42 is an arrangement diagram of a sewing machine controlling apparatus concerned with the present embodiment, wherein 300 indicates an angle setting circuit acting as angle setting means, 525 represents a sewing machine control circuit, and S7 denotes an angle storage signal. It is to be understood that the other parts are identical to those in previous embodiments and will not be described.
FIG. 43 is a block diagram showing said sewing machine control circuit 525, and FIG. 44 is a flowchart of software incorporated in the sewing machine control circuit 525. Control is exercised in accordance with this flowchart when the angle storage signal S7 is entered. It is to be understood that FIG. 45 is an operation timing chart. In this embodiment, switching on the angle storage signal S7 causes an angle measurement circuit 362 to start angle measurement, and turning the machine pulley 4 by hand counts the angle. By switching the angle storage signal S7 on again, the angle measurement is terminated and the angle measured is transferred from the angle measurement circuit 362 to the angle setting circuit 300 and is stored there.
Operation will now be described in accordance with the flowchart in FIG. 44 and the timing chart in FIG. 45.
Starting at step 500, it is judged at step 501 whether the angle storage signal S7 has switched on or not. If the signal is off, the sequence proceeds to step 505 and no operation is performed. If the angle storage signal S7 is on at step 501, the sequence progresses to step 502, where the rotary angle is measured. Further at step 503, it is judged again whether the angle storage signal S7 has switched on or not. If not on, the sequence moves on to step 505. If on, the sequence advances to step 504, where the rotary angle measured is transferred and stored to the angle setting circuit 300.
According to the apparatus in this embodiment, the machine needle rotates reversely to return upward when it is desired to change the position of the material or change the material after the machine needle has been lowered to a position immediately before the material, whereby it is easy to shift the position of the material or to change the material. It is to be noted that the stitching start or thread trimmer start operation is identical to those described in said conventional example and will not be described here.
A twentieth embodiment of the invention will now be described. The arrangement of the apparatus in this embodiment is identical to that in Embodiment 19and will not be described.
After the threads have been trimmed by the thread trimmer start signal S2, the sewing machine 1 enters a rotary angle measurement mode, wherein the angle of the machine pulley 4 hand-turned is measured. When the angle storage signal S7 is switched on, the rotary angle measured is transferred and stored to the angle setting circuit 300.
The operation of the apparatus concerned with Embodiment 19will now be described in accordance with a flowchart in FIG. 46 and a timing chart in FIG. 47. Starting at step 510, it is judged at step 511 whether the sewing machine 1 has finished thread trimming or not. If not, the sequence advances to END of step 515 and no further operation is performed.
If the sewing machine 1 has done thread trimming at step 511, the rotary angle is measured at step 512. If the angle storage signal S7 has switched on at step 513, the rotary angle measured is transferred and stored to the angle setting circuit 300. If the angle storage signal S7 is not on at step 513, the processing advances to step 515 and the angle is not stored.
According to the apparatus in this embodiment, the machine pulley 4 is hand-turned and the machine needle is actually brought to the stop position immediately before the material to store that position, whereby angle setting need not be repeated many times.
A twenty-first embodiment of the invention will now be described. The arrangement of the apparatus in this embodiment is also identical to that in said Embodiment 18 as in Embodiment 19 and will not be described.
After the threads have been cut under the control of the thread trimmer start signal S2 in this embodiment, the sewing machine 1 goes into a rotary angle measurement mode, wherein the angle of the machine pulley 4 hand-turned is measured. When the angle storage signal S7 is switched on, the rotary angle measured is compared with a given value. If it is less than the given value, the sewing machine 1 rotates in the forward direction by the jogging angle set by the angle setting circuit 300 and comes to a stop. If the rotary angle measured is equal to or more than the given value, it is measured and transferred and stored to the angle setting circuit 300.
The operation of the apparatus concerned with this Embodiment 21 will now be described in accordance with a flowchart in FIG. 48 and timing charts in FIGS. 49 and 50.
Starting at step 520, it is judged at step 521 whether the sewing machine 1 has finished thread trimming or not. If not, the sequence advances to END of step 527 and no operation is performed.
If thread trimming has been done at step 521, the processing goes forward to step 522, where the measurement of the rotary angle is initiated. At step 523, it is judged whether the jogging signal S4 has turned on or not. If not on, the sequence progresses to END of step 527.
If the jogging signal S4 has turned on at step 523, the sequence proceeds to step 524, where it is judged whether the rotary angle of the sewing machine 1 is equal to or more than a given value. If it is less than the given value, the sequence progresses to step 526, where the sewing machine 1 rotates forward by the jogging angle set by the angle setting circuit 300 and comes to a stop as shown in the timing chart in FIG. 49.
If that angle is not less than the given value, the sequence progresses to step 525, where the rotary angle measured is transferred and stored to the angle setting circuit 300 as shown in the timing chart in FIG. 50. The apparatus in this embodiment is lower in the number of entering the reverse rotation signals S5 and thus shorter in working time than the apparatus concerned with.
A twenty-second embodiment of the invention will now be described. FIG. 51 is an arrangement diagram of a sewing machine controlling apparatus according to the present embodiment, wherein 526 indicates a sewing machine control circuit detailed in FIG. 52, S8 designates an ultra-low speed input signal, and S9 denotes an ultra-low speed reverse rotation input signal.
In the present embodiment, when the ultra-low speed input signal S8 is entered in FIG. 51, the sewing machine 1 rotates forward at ultra-low speed (0.1 to 50 revolutions/second) lower than the low speed (100 to 300 revolutions/second) of the conventional sewing machine, the rotary angle is measured, and when the ultra-low speed input signal S8 is switched off, the rotary angle measured is transferred and stored to the angle setting circuit 300.
The operation of the apparatus in the present embodiment will now be described in accordance with a block diagram in FIG. 52. When the ultra-low speed input signal S8 is entered into the run signal input circuit 301 of the sewing machine control circuit 526, an ultra-low speed command signal VLKO is output from the speed command circuit 304 via a run control circuit 370, and further the run signal SRT is output from the rotation/stop command circuit 305 to run the motor 2 at ultra-low speed. At the same time, the run control circuit 370 commands the angle measurement circuit 362 to measure the angle. This starts the measurement of the angle.
When the ultra-low speed input signal S8 is switched off, the run signal input circuit 301 commands the ultra-low speed command signal VLKO to be set to 0 by the speed command circuit 304 via the run control circuit 370 and the rotation/stop command circuit 305 switches the run signal SRT off and outputs the brake signal BK for a given time to stop the sewing machine 1. Simultaneously, the run control circuit 370 exercises control to cause the angle measurement circuit 362 to stop the measurement of the angle and transfer the angle measured to the angle setting circuit 300, whereby the jogging angle is stored to the angle setting circuit 300. Subsequently, when the stitching start signal S1 is entered, the sewing machine 1 rotates by the jogging angle stored in the angle setting circuit 300 and comes to a stop.
The operation of the apparatus in the present embodiment will be described in accordance with a flowchart in FIG. 53. Starting at step 600, it is judged at step 601 whether the ultra-low speed input signal S8 has turned from ON to OFF. If not, the sequence advances to step 603, where it is judged whether the ultra-low speed input signal S8 is on or not. If the ultra-low speed input signal S8 is on, the sequence moves to step 604, where the ultra-low speed command signal VLKO is set to 1 and the run signal SRT is switched on, whereby the sewing machine 1 rotates at ultra-low speed and the rotary angle is measured at step 605.
If the ultra-low speed input signal S8 has turned from ON to OFF at step 601, the ultra-low speed command signal VLKO is set to 0, the run signal SRT is switched off, and the brake signal BK is switched on for a given time at step 602 to stop the sewing machine 1, and the rotary angle measured is transferred and stored to the angle setting circuit 300. It is to be understood that the stitching start or thread trimmer start operation is identical to that described in said conventional example and will not be described here.
When the ultra-low speed input signal S8 is switched on in a timing chart in FIG. 54, the run signal SRT and the ultra-low speed command signal VLKO are output to run the sewing machine 1 at ultra-low speed and measure the rotary angle beginning with the start of operation.
When the ultra-low speed input signal S8 is switched off, the run signal SRT and the ultra-low speed command signal VLKO are switched off, the brake signal BK is switched on for a given time, and the angle measured is transferred and stored to the angle setting circuit 300. By switching the ultra-low speed input signal S8 on again when the point of the machine needle has not reached the immediately-before-the-material position which was the destination, the sewing machine 1 rotates at ultra-low speed similarly and the rotary angle is counted in addition to the previous angle. When the ultra-low speed input signal S8 is switched off, the sewing machine 1 stops and the angle measured is transferred and stored to the angle setting circuit 300 similarly. It is to be understood that the stitching start or thread trimmer start operation is identical to that described in said conventional example and will not be described here.
A sewing machine controlling apparatus concerned with a twenty-third embodiment of the invention will now be described. In this embodiment, the arrangement of the sewing machine controlling apparatus is identical to that in Embodiment 22 in FIGS. 51 and 52 and will not be described. When the ultra-low speed input signal S8 is entered in FIG. 51, the sewing machine 1 rotates forward at ultra-low speed, the rotary angle is measured, and when the ultra-low speed input signal S8 is switched off, the rotary angle measured is transferred and stored to the angle setting circuit 300. When the ultra-low speed reverse rotation input signal S9 is entered, the sewing machine 1 rotates reversely at ultra-low speed, the rotary angle is measured, and when the ultra-low speed reverse rotation input signal S9 is switched off, a difference between the forward and reverse rotation angles is calculated and the rotary angle measured is transferred and stored to the angle setting circuit 300.
The operation of the apparatus in the present embodiment will now be described in accordance with the block diagram in FIG. 52. The operation at a time when the ultra-low speed input signal S8 is entered is identical to that in Embodiment 22. When the ultra-low speed reverse rotation signal S9 is entered into the run signal input circuit 301 of the sewing machine control circuit 526, the ultra-low speed command signal VLKO is output from the speed command circuit 304 via the run control circuit 370, further the run signal SRT is output from the rotation/stop command circuit 305, and the reverse rotation signal R is switched on to run the sewing machine 1 in the reverse direction at ultra-low speed.
At the same time, the run control circuit 370 commands the angle measurement circuit 362 to measure the angle. This starts the measurement of the angle.
When the ultra-low speed reverse rotation input signal S9 is switched off, the run signal input circuit 301 commands the ultra-low speed command signal VLKO to be switched off by the speed command circuit 304 via the run control circuit 370 and the rotation/stop command circuit 305 switches off the run signal SRT and the reverse rotation signal R and outputs the brake signal BK for a given time to stop the sewing machine 1.
Simultaneously, the run control circuit 370 exercises control to cause the angle measurement circuit 362 to stop the measurement of the angle and transfer the angle measured to the angle setting circuit 300, whereby the jogging angle is stored to the angle setting circuit 300. Subsequently, when the jogging signal S4 is entered, the sewing machine 1 rotates by the jogging angle stored in the angle setting circuit 300 and comes to a stop.
The operation of the apparatus given in Embodiment 23 will be described in accordance with a flowchart in FIG. 55. Starting at step 610, it is judged at step 611 whether or not the ultra-low speed input signal S8 has turned from ON to OFF. If not, the sequence advances to step 613, where it is judged whether the ultra-low speed input signal S8 is on or not. If the ultra-low speed input signal S8 is on, the sequence moves to step 614, where the ultra-low speed command signal VLKO is switched on, the run signal SRT is switched on, and the reverse rotation signal R is switched off, whereby the sewing machine 1 rotates forward at ultra-low speed and the rotary angle is measured at step 615.
If the ultra-low speed input signal S8 has turned from ON to OFF at step 611, the ultra-low speed command signal VLKO is switched off, the run signal SRT is switched off, and the brake signal BK is switched on for a given time at step 612 to stop the sewing machine 1 and to transfer and store the rotary angle measured to the angle setting circuit 300.
At step 616, it is judged whether the ultra-low speed reverse rotation input signal S9 has turned from ON to OFF. If not, the sequence advances to step 618, where it is judged whether the ultra-low speed reverse rotation input signal S9 is on or not. If the ultra-low speed reverse rotation input signal S9 is on, the sequence moves to step 618, where the ultra-low speed command signal VLKO is switched on, the run signal SRT is switched on, and the reverse rotation signal R is set to 1, whereby the sewing machine 1 reverses at ultra-low speed and the rotary angle is measured at step 620.
If the ultra-low speed reverse rotation input signal S9 has turned from ON to OFF at step 616, the ultra-low speed command signal VLKO is switched off, the run signal SRT is switched off, and the brake signal BK is switched on for a give time at step 617 to stop the sewing machine 1 and to transfer and store the rotary angle measured to the angle setting circuit 300.
When the ultra-low speed input signal S8 is first switched on in a timing chart in FIG. 56, the run signal SRT and the ultra-low speed command signal VLKO are switched on and the reverse rotation signal R is switched off to run the sewing machine 1 forward at ultra-low speed and measure the rotary angle beginning with the start of operation.
When the ultra-low speed input signal S8 is switched off, the run signal SRT and the ultra-low speed command signal VLKO are switched off, the brake signal BK is switched on for a given time, and the angle measured is transferred and stored to the angle setting circuit 300. By switching on the ultra-low speed reverse rotation input signal S9 when the point of the machine needle is lower than the immediately-before-the-material position which was the destination, the sewing machine 1 reverses at ultra-low speed and the rotary angle is subtracted in addition to the previous angle. When the ultra-low speed reverse rotation input signal S9 is switched off, the sewing machine 1 stops and the angle measured is transferred and stored to the angle setting circuit 300 similarly. According to the apparatus in the present embodiment, the sewing machine 1 can be actually rotated under the control of the ultra-low speed input signal to match the point of the machine needle with the position immediately before the material, with the machine pulley 4 untouched, whereby a safe apparatus is provided.
A sewing machine controlling apparatus concerned with a twenty-fourth embodiment of the invention will now be described. FIG. 57 is an arrangement diagram illustrating the sewing machine controlling apparatus concerned with the present embodiment, wherein 527 indicates a sewing machine control circuit which is detailed in FIG. 58.
In this embodiment, when the stitching start signal S1 is entered into the run signal input circuit 301 in FIG. 58, it passes through the run control circuit 380 and reaches the rotation/stop command circuit 305, which then outputs the run signal SRT to run the sewing machine 1 at the speed under the control of the speed command signal VC according to the toe-down degree of the pedal 10.
During the rotation of the sewing machine 1, speed deviation between the speed command signal VC and the rotary speed of the sewing machine 1, which has been converted by the speed detection circuit 381 from the position detection signal FG of the needle position detector 3 entered via the needle position input circuit 312, is operated on by a deviation operation circuit 382. When the speed deviation is large, i.e., when the load of the sewing machine 1 has increased, peak torque, i.e., the time when the material is pierced, is detected by a peak detection circuit 383. When the peak torque is detected by the peak detection circuit 383, the rotary angle at which the torque peaked is measured by the angle measurement circuit 362. The material-to-machine needle angle at the time of immediately-before-the-material stop set to the angle setting circuit 300 is subtracted from the rotary angle at which the torque peaked, and the result of subtraction is stored into the jogging angle area of the angle setting circuit 300.
When the jogging signal S4 is entered after the machine needle has stopped at the UP position, the sewing machine 1 rotates the jogging angle stored and the needle point of the sewing machine 1 stops at a position immediately before the material.
FIG. 59 is an operation flowchart of the sewing machine controlling apparatus 527 according to the present embodiment.
Starting at step 700, it is judged at step 701 whether the stitching start signal S1 is on or not. If it is on, the processing advances to step 702, where the run signal SRT is switched on to start the sewing machine 1 running. At step 703, a difference between the speed command signal VC and a speed feedback signal VF, i.e., speed deviation VD, is operated on.
At step 704, the peak of the speed deviation VD is detected. When the torque peaks, the material-to-machine needle angle at the time of immediately-before-the-material stop is subtracted from the rotary speed of the sewing machine 1 at which the torque peaks, i.e., the angle at a time when the material is pierced, at step 705. At step 706, the result of subtraction is transferred and stored to the angle setting circuit 300.
If the stitching start signal S1 is not on at step 701, the run signal SRT is switched off to stop the sewing machine 1.
FIG. 60 is an operation timing chart. When the pedal 10 is toed down, the stitching start signal S1 is switched on. As the speed command signal VC increases according to the toe-down degree of the pedal 10, the speed control circuit 13 runs the motor 2 to exercise feedback control so that the speed of the sewing machine 1 matches the speed command signal VC.
When the machine needle point has reached the surface of the material, the peak torque is generated and the speed feedback signal VF reduces slightly. The speed deviation VD between this reduced speed feedback signal VF and the speed command signal VC peaks when the material is pierced with the machine needle. The material-to-machine needle angle at the time of immediately-before-the-material stop in the angle setting circuit 300 is subtracted from the angle at the time of piercing the material from the angle measurement circuit 362, and the result of subtraction is transferred and stored to the jogging angle area of the angle setting circuit 300. When the material-to-needle angle is preset, the apparatus according to the present embodiment does not require the immediately-before-the-material stop position to be re-adjusted if the thickness of the material changes. It is to be noted that the stitching start or thread trimmer start operation is as described in said conventional example and will not be described here
A sewing machine controlling apparatus concerned with a twenty-fifth embodiment of the invention will now be described. In this embodiment, the arrangement diagram of the sewing machine controlling apparatus is identical to that in FIG. 57 of Embodiment 23 and will not be described.
In this Embodiment 25, when the stitching start signal S1 is entered into the run signal input circuit 301 in FIG. 58, it passes through the run control circuit 380 and reaches the rotation/stop command circuit 305, which then outputs the run signal SRT to run the sewing machine 1 at the speed under the control of the run signal SRT according to the toe-down degree of the pedal 10.
During the rotation of the sewing machine 1, speed deviation between the speed command signal VC and the rotary speed of the sewing machine 1, which has been converted by the speed detection circuit 381 from the position detection signal FG of the needle position detector 3 entered via the needle position input circuit 312, is operated on by the deviation operation circuit 382. When the speed deviation is large, i.e., when the load of the sewing machine 1 has increased, peak torque, i.e., the time when the material is pierced, is detected by the peak detection circuit 383. When the peak torque is detected by the peak detection circuit 383 and the machine needle is in the range from the UP position to the DOWN position, the rotary angle at which the torque peaked is measured by the angle measurement circuit 362. The material-to-machine needle angle at the time of immediately-before-the-material stop set to the angle setting circuit 300 is subtracted from the rotary angle at which the torque peaked, and the result of subtraction is stored into the jogging angle area of the angle setting circuit 300.
When the jogging signal S4 is entered after the machine needle has stopped at the UP position, the sewing machine 1 rotates the jogging angle stored and the needle point of the sewing machine 1 stops at a position immediately before the material.
FIG. 61 is an operation flowchart of the sewing machine controlling apparatus 527 according to the present embodiment 25. Starting at step 710, it is judged at step 711 whether the stitching start signal S1 is on or not. If it is on, the processing advances to step 712, where the run signal SRT is switched on to start the sewing machine 1 running. At step 713, a difference between the speed command signal VC and the speed feedback signal VF, i.e., speed deviation VD, is operated on. At step 714, it is judged whether or not the machine needle is in the range from the UP position to the DOWN position. If the needle is in that range, the sequence progresses to step 715. If not, the sequence proceeds to step 718.
At step 715, the peak of the speed deviation VD is detected. When the torque peaks, the material-to-machine needle angle at the time of immediately-before-the-material stop is subtracted from the rotary speed of the sewing machine 1 at which the torque peaks, i.e., the angle at a time when the material is pierced, at step 716. At step 717, the result of subtraction is transferred and stored to the angle setting circuit 300.
If the stitching start signal S1 is not on at step 711, the run signal SRT is switched off to stop the sewing machine 1.
FIG. 60 is an operation timing chart. When the pedal 10 is toed down, the stitching start signal S1 is switched on. As the speed command signal VC increases according to the toe-down degree of the pedal 10, the speed control circuit 13 runs the motor 2 to exercise feedback control so that the speed of the sewing machine 1 matches the speed command signal VC.
When the machine needle point has reached the surface of the material, the peak torque is generated and the speed feedback signal VF reduces slightly. The speed deviation VD between this reduced speed feedback signal VF and the speed command signal VC peaks when the material is pierced with the machine needle. The material-to-machine needle angle at the time of immediately-before-the-material stop in the angle setting circuit 300 is subtracted from the angle at the time of piercing the material from the angle measurement circuit 362, and the result of subtraction is transferred and stored to the jogging angle area of the angle setting circuit 300.
To prevent the peak torque generated to pull the machine thread when the machine needle rises except when the material is pierced from being misrecognized, a flag UDF indicating that the needle is in the range from the UP position to the DOWN position is provided so that the angle at the peak torque time may only be read when the flag UDF is 1. According to the apparatus in this embodiment, the torque which peaks within the position where the material is pierced with the machine needle is removed as noise, whereby the fabric surface position can be detected reliably.
The needle position detector 3 for detecting the rotary angle of the sewing machine 1 in each of the previous embodiments is not limited to the one provided on the machine shaft and may be provided on the motor shaft, for example, to calculate the angle of the machine shaft according to the pulley ratio.
Also, the motor 2 and the sewing machine 1 designed to be driven via the belt 6 may be coupled directly. Further, the two signals, the needle UP position signal UP and the needle DOWN position signal DN, which were used for calculation, may be replaced by one signal, i.e., the position detection signal FG of the needle position detector 3. Also, the one angle of the needle bar, i.e., the jogging angle or the reverse rotation angle, may be separately provided for forward rotation and reverse rotation.
Also, in addition to the jogging angle and the reverse rotation angle set individually, another signal indicating the stop position may be provided for the needle position detector 3. Also, the reverse rotation angle set may be substituted by the needle UP position signal UP, the needle DOWN position signal DN, or the needle position signal.
The one jogging angle or one reverse rotation angle set may be two or more and selecting means may be provided to select from among those set. The jogging angle setting circuit or the reverse rotation angle setting circuit may be comprised of a seven-segment LED and a switch or may use a variable resistor. | A sewing machine having a motor drive operating in response to a controller to rotate in forward and reverse rotation directions. A jogging angle may be set and the drive operated automatically for rotation in forward and/or reverse directions as a function of various operating conditions so that the needle is stopped in an optimum position for piercing a material. | 3 |
BACKGROUND
[0001] The present exemplary embodiment relates generally to lighting. It finds particular application in conjunction with light emitting diodes (or LEDs) that may be used for general lighting and air purification and will be described with particular reference thereto. However, it is to be appreciated that the present exemplary embodiment is also amenable to other like applications.
[0002] By way of background, air quality is a health concern, especially in frequently visited public places, such as hospitals and schools. With regard to disinfecting the air in such places, air purifiers have been used to decompose toxic volatile organic compounds (VOCs) and living organisms like bacteria and viruses. Current solutions, such as air filtration or UV (ultraviolet) lamp irradiation, however, require forced air circulation by means of fans and motors. And direct UV illumination is not always possible in occupied places. Therefore, alternative sources have been contemplated.
[0003] Recently, light emitting diode (LED) lamps have been employed for various lighting applications. LED lamps are preferred because they consume less power (watts) than their fluorescent and incandescent counterparts, which results in an energy savings.
[0004] Thus, there is a need for a lighting device combined with an air purification feature, which does not, for example, use harmful UV radiation or incorporate a fan.
BRIEF DESCRIPTION
[0005] An improved LED lighting device with an air purification feature is disclosed herein. At least one function of the device is to provide high quality directional light for task lighting, accent lighting, and/or general lighting purposes. An additional function of the device is to decompose VOCs and/or destroy microbes in the ambient air. The heat generated by white LEDs is utilized to generate air flow through the device. The geometry of the device is designed to utilize the chimney effect and maximize volumetric flow. The circulated air may be purified, for example, by a photocatalytic layer applied to the interior surface of the device. The lighting device can be built into pendant luminaires or lamps, for example, thus ensuring vertical orientation of the light module. The exemplary embodiments may be applied in public places, hospitals, ward rooms, horticultural environments (e.g., greenhouses), livestock growing places (e.g., stables) and other locations where a cost effective air disinfection method is needed.
[0006] In one embodiment, a lighting and air purification apparatus is provided. The apparatus includes a body having a top end and a bottom end and an interior surface coated with a photocatalytic layer for purifying air, wherein the body also includes a plurality of inlet openings spaced near the bottom end configured to draw in ambient air and at least one outlet opening at the top end configured to release heated air. The apparatus also includes a heat conductive element at the bottom end of the body and a first set of LEDs on a lower surface of the heat conducting element and a second set of LEDs on an upper surface of the heat conducting element, wherein the first set of LEDs is configured to provide light and the second set of LEDs is configured to provide light having an emission that is greater than 400 nm for air purification. The first set of LEDs may be configured to provide light between 50 and 20000 lumens.
[0007] Optionally, the body comprises a conical member and the top end of the conical member has an upper diameter that is smaller than a lower diameter of the bottom end of the conical member. In that case, the outlet opening may comprise a round hole and the inlet openings may comprise round holes spaced radially around the bottom end of the conical member. Or the outlet opening may comprise a round hole and the inlet openings may comprise rectangular openings oriented diagonally and spaced radially around the bottom end of the conical member.
[0008] The thickness of the photocatalytic layer may be configured to allow transmission of visible light. The photocatalytic layer may comprise (1) doped titanium oxide that is activated by light from the second set of LEDs, (2) single or mixed oxides of metals selected from the group of Ti, Zn, Zr, Ce, V, W, Bi—W, W—Cd, Zn—In, Bi—Cd—In, and Pb—Bi—Nb, or (3) an oxide-nitride compositions selected from the group of GaN—ZnO and Ge 3 N 4 —RuO 2 . The photocatalytic layer may be configured to oxidize harmful organic molecules (VOCs) and destroy microbes in the ambient air drawn in through the inlet openings.
[0009] The heat conductive element may comprise a metal plate, wherein each set of LEDs is attached by screws. In addition, the heat conductive element may comprise a heat conductive plate with a metal core printed circuit board attached to each side, wherein the metal core printed circuit board on the bottom side is substantially as large as the heat conductive plate and the metal core printed circuit board on the inner side is smaller than the heat conductive plate for creating a heat bridge between the heat conductive plate and air moving inside the conical member.
[0010] The body may comprise a conical member that is transparent and the second set of LEDs may be white LEDs with a high 405 nm component. The apparatus may also include optical elements at the bottom end of the body for directing light from the first set of LEDs. The body may also comprise a linear member and include optical elements for directing light from the first set of LEDs.
[0011] In another embodiment, a lighting and air purification apparatus is provided. The apparatus includes a body having a top end and a bottom end and an interior surface coated with a photocatalytic layer for purifying air, wherein the body also includes a plurality of inlet openings spaced near the bottom end configured to draw in ambient air and at least one outlet opening at the top end configured to release heated air. The apparatus also includes a mechanical holder at the bottom end of the body that is configured to provide mechanical and electrical connection of an LED module to the body and a first set of LEDs mounted in the LED module, wherein the first set of LEDs is configured to provide light in a downward direction. The apparatus further includes a second set of LEDs mounted on an upper surface of a heat conducting element, wherein the second set of LEDs is configured to provide light in an upward direction and having an emission that is greater than 400 nm for air purification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The following description and drawings set forth certain illustrative implementations of the disclosure in detail, which are indicative of several exemplary ways in which the various principles of the disclosure may be carried out. The illustrative examples, however, are not exhaustive of the many possible embodiments of the disclosure. Other objects, advantages and novel features of the disclosure will be set forth in the following detailed description of the disclosure when considered in conjunction with the drawings, in which:
[0013] FIG. 1 is a schematic view of a preferred embodiment of a lighting device in accordance with the exemplary embodiments;
[0014] FIG. 2 is a perspective view of the lighting device incorporated into a pendant luminaire;
[0015] FIG. 3 is a perspective view of the lighting device incorporated into a pendant lamp;
[0016] FIG. 4 is a schematic view of an alternative embodiment of the lighting device;
[0017] FIG. 5 is a perspective view of the lighting device incorporated into a table lamp;
[0018] FIG. 6 is a perspective view of the lighting device incorporated into a spot lamp fixture;
[0019] FIG. 7 is a schematic view of a linear lighting device in accordance with the exemplary embodiments;
[0020] FIG. 8 is graph showing test results for a 405 nm light source and an uncoated test surface (direct), and test surfaces coated with undoped (TiO2) and nano-Ag doped titania coatings;
[0021] FIG. 9 is a graph showing the efficiency of the cooling system for a 15 W—larger enclosure lighting device;
[0022] FIG. 10 is a graph showing the efficiency of the cooling system for a 35 W larger enclosure lighting device;
[0023] FIG. 11 is a graph showing the efficiency of the cooling system for a 14 W smaller enclosure lighting device; and
[0024] FIG. 12 is a schematic view of another embodiment of the lighting device.
DETAILED DESCRIPTION
[0025] One or more embodiments or implementations are hereinafter described in conjunction with the drawings, where like reference numerals are used to refer to like elements throughout, and where the various features are not necessarily drawn to scale.
[0026] With reference to FIG. 1 , a schematic view of a preferred embodiment of a lighting device 100 is shown. The lighting device 100 generally includes a heat conductive layer and/or a circuit board 102 assembled at the bottom end 103 of a body (or housing) 104 , which acts as a chimney, inducing an upward flow of air in the lighting device 100 . Generally, as shown in FIG. 1 , the body 104 is conical in shape. However, other configurations and/or shapes may be implemented to the extent that they help to provide a chimney effect, as described more fully below,
[0027] Suitably, one or more LEDs 106 may be mounted on the lower surface of the heat conductive layer 102 . The LEDs 106 can be phosphor-coated LEDs, RGB LEDs, monochromatic LEDs, or a combination of phosphor and monochromatic LEDs. The light produced by the LEDs 106 may be used for various types of lighting applications, including task lighting, accent lighting, general lighting and/or horticultural lighting. Task lighting is mainly functional and is usually the most concentrated, for purposes such as reading or inspection of materials. Accent lighting is mainly decorative, intended to highlight pictures, plants, or other elements of interior design or landscaping. General lighting fills in between the two and is intended for general illumination of an area. Indoors, this would be a basic lamp on a table (task lighting) or floor, or a fixture on the ceiling (general lighting).
[0028] There is generally no restriction regarding the number and arrangement of the LEDs, since the heat conductive layer 102 spreads any heat equally. That is, the LEDs 106 may be arranged so as to correspond to the light pattern required. Any suitable lens can be used, and the arrangement of the LEDs 106 is not limited in this application. The lighting device 100 may generally provide a minimum of 50 lumens and a maximum of 20000 lumens but preferably between 600 and 10000 lumens.
[0029] The lighting device 100 also includes one or more auxiliary LEDs 108 mounted on the upper side of the heat conductive layer 102 . The auxiliary LEDs 108 generally have an emission that is greater than 400 nm and is preferably at 405 nm (violet) or 450-460 nm (blue). In the case of a transparent conical member or in indirect lighting applications, the LEDs 108 can be white LEDs with a high 405 nm component. The power consumption may be between 1 and 90% of the LEDs on the lower surface of the circuit board 106 , but preferably between 1 and 20%.
[0030] The heat conductive layer 102 has at least two functions: (1) it should distribute heat generated by the LEDs ( 106 , 108 ) equally, and (2) it should provide an electrical connection for the LEDs ( 106 , 108 ). In FIG. 1 the heat conductive layer 102 comprises a metal plate, with each side of LEDs ( 106 , 108 ) being attached by soldering, mechanical fixing or chemical bond. It is to be understood, however, that the element 102 may also comprise a heat conductive plate (e.g., aluminium, copper, etc.), and on each side a MCPCB (metal core printed circuit board) or other adequate holder (Chip on Board technology) is attached, or a holder surface can be created on the heat conductive element in such a way that LED modules can be attached in a twist and lock style creating electrical and thermal connection, or a combination of all the above mentioned methods may be employed. The attachment of the holder can be made with mechanical fixing or a chemical bond. The holder on the bottom side can be as large as the plate, since it has an effect only with respect to equal heat distribution. But for the inner side (for the photocatalytic LEDs 108 ) it should be smaller to help ensure the best heat bridge between the plate and the air moving inside the chimney. The holder(s) provide an electrical connection for the LEDs ( 106 , 108 ), which can be serial or parallel. The LEDs ( 106 , 108 ) may be attached by soldering, chemical bond, or mechanical fixing.
[0031] The LEDs ( 106 , 108 ) generate heat during operation of the lighting device 100 . Based on an electrical model analogy and “Ohm's Thermal Law,” the relationship can be represented by the following formula:
[0000] T j −T a =R thja ×( V d ×I d ) (1)
[0000] where T j =LED junction temperature, T a =Ambient temperature, R thja =Thermal resistance junction to ambient, V d =LED forward voltage, and I d =LED forward current.
[0032] The conical member 104 typically includes at least one outlet opening 110 at the upper end and a plurality of small openings (or apertures) 112 spaced near the bottom of the conical member 104 . For example, as shown in FIG. 1 , the inlet openings 112 may be generally round holes. However, other configurations may be implemented to the extent that they help to provide a chimney effect. For example, the inlet openings 112 may be rectangular slots oriented vertically, diagonally, and/or horizontally around the bottom end of the conical member 104 .
[0033] In operation, ambient air is drawn in through a plurality of inlet openings 112 near the bottom end 103 of the conical member 104 . Heated air flows upwards through a top opening 110 at the top end 113 of the conical member 104 , at least in part due to the “chimney” effect. To function properly, the minimum temperature needed is approximately 35° C. with 4-5 Watts of electrical power.
[0034] It is to be understood that the “chimney” effect (also called the “buoyancy” or “stack” effect) is based on the natural tendency of the air to move from high to low pressures (natural ventilation). The warm air rises naturally, producing air movement through the building. The existence of a chimney is increasing this effect for several reasons. Due to the lower effective section, the air speed is accelerated in the chimney. Consequently, the pressure is lowering in this section (principle of energy conservation—Venturi effect). Due to the higher difference of pressure, the air movement is accelerated. The chimney creates a bigger difference in height, thus increasing the Venturi effect and also the difference in temperature from the air intake to the exhaust point. Note that the presence of wind conditions (even slight) would have the effect of lowering the pressure at the chimney exhaust and thus increasing the air extraction efficiency.
[0035] The conical member 104 has at least two functions in this device: (1) it provides a type of chimney, which directs the warm air flow in an upward direction, and (2) it provides a holding surface for a photocatalytic layer 114 , which helps to create a photocatalytic effect by exposing the ambient air in the conical member 104 , for example, to 405 nm light. The conical member 104 can be composed of a heat conductive material, such as metal. In that case, the air flow in the system is relatively smaller, but the cooling surface of the light source(s) is increased. Such a configuration is generally recommended for higher wattages. On the other hand, if the conical member 104 is composed of a material that is not heat conductive (for example, plastic), the air flow is increased, but the cooling surface of the light source(s) is smaller. This configuration is generally recommended for lower wattages. The material used to make the conical member 104 can be transparent (for example, glass) so that the indirect lighting of the system (i.e., the second set of LEDs) can be used for general lighting. The height of the conical member 104 shall vary depending on the total surface area of the system. More particularly, the ratio of the height of the conical member (H) to the total area of the system (A) is generally between 0.005 and 0.5.
[0036] The bottom diameter of the conical member is typically larger than the upper diameter so as to maximize the flow of air through the conical member 104 . The surface area of the inlet openings 112 generally depends on the total surface area of the whole system. Thus, the ratio of the inlet hole surface area/total surface area generally has a minimum of 0.001 and a maximum of 0.4. The inlet holes 112 typically have no specific shape requirement, and they can be any combination of a semicircle, a circle, a square, a rectangle, etc.
[0037] The air stream within the conical member 104 is preferably in contact with a photocatalytic layer 114 coated on the interior surface of the conical member 104 . The surface coverage of substrates by photocatalysts is above 20 ug/cm 2 , but it is not necessarily uniform. The photocatalytic layer 114 may contain doped titanium oxide, which is activated by the light of the auxiliary LEDs 108 . But other any other typical photocatalytic material can be considered, including but not limited to:
Single or mixed oxides of metals (doped or undoped): Ti, Zn, Zr, Ce, V, W, Bi—W, W—Cd, Zn—In, Bi—Cd—In, Pb—Bi—Nb Oxide-nitride compositions: GaN—ZnO, Ge 3 N 4 —RuO 2
The activated photocatalytic layer 114 suitably oxidizes harmful organic molecules (VOCs) and destroys microbes in the air.
[0040] It is noted that 405 nm is an adequate wavelength to kill bacteria/germs if the illuminated surface is coated with the photocatalytic layer 114 absorbing at 405 nm. Some bacteria can be effectively killed by a mere 405 nm irradiation without a photocatalysator.
[0041] In another embodiment the conical member 104 of the lighting device 100 is composed of a transparent material, such as glass or plastic. In this embodiment, the coating thickness of the photocatalytic layer 114 is set to allow transmission of visible light. The auxiliary LEDs 108 can be, in this case, white LEDs having a significant emission at 405 nm or 450 nm. The 405 nm or 450 nm radiation is substantially absorbed by the photocatalytic layer 114 . The advantage of this embodiment is that scattered white light is emitted upwards from the conical element 104 providing indirect light, which is preferred in some lighting applications. Generally, the device 100 could still have the white LEDs on the bottom surface of the circuit board 102 .
[0042] The lighting device 100 can be incorporated into a pendant luminaire 200 (see FIG. 2 ) or a lamp 300 (see FIG. 3 ), thus ensuring vertical orientation of the lighting device 100 . Generally, the lighting devices shown in FIGS. 2 and 3 would operate in the same manner as described above.
[0043] With reference now to FIG. 4 , a schematic view of an alternative lighting device 400 is shown, The lighting device 400 is generally similar in structure to the device 100 shown in FIG. 1 and operates in a similar manner. The differences between the lighting devices ( 100 , 400 ) will be described in greater detail below. For example, the alternative lighting device 400 similarly includes a heat conductive layer and/or a circuit board 402 assembled at the bottom end 403 of a housing or body 404 , which generally acts as a chimney, inducing an upward flow of air in the lighting device 400 . Generally, as shown in FIG. 4 , the body 404 is conical in shape. However, other configurations may be implemented to the extent that they help to provide a chimney effect.
[0044] Suitably, one or more LEDs 406 may be mounted on the lower surface of the circuit board 402 . The LEDs 406 can be phosphor-coated LEDs, RGB LEDs, monochromatic LEDs, or a combination of phosphor and monochromatic LEDs. The light produced by the LEDs 406 may be used for various types of lighting applications, including task lighting, accent lighting, general lighting and/or horticultural lighting. The system may provide a minimum of 50 lumens and a maximum of 20000 lumens, but preferably between 600 and 10000 lumens.
[0045] The lighting device 400 also includes one or more auxiliary LEDs (not shown) mounted on the upper side of the circuit board 402 . The auxiliary LEDs generally have an emission that is greater than 400 nm and is preferably at 405 nm (violet) or 450-460 nm (blue). In the case of a transparent conical member or in indirect lighting applications, the LEDs can be white LEDs with a high 405 nm component.
[0046] The conical member 404 typically includes at least one outlet opening (not shown) at the upper end and a plurality of small openings (or apertures) 412 spaced radially near the bottom end 403 of the conical member 404 . For example, as shown in FIG. 4 , the inlet openings 412 may be generally rectangular openings oriented diagonally around the bottom end of the conical member 404 . However, other configurations may be implemented to the extent that they help to provide a chimney effect.
[0047] As with the lighting device 100 of FIG. 1 , the LEDs of the alternative lighting device 400 generate heat during operation. Ambient air is drawn in through the inlet openings 412 . The heated air flows upwards and out through an opening 414 at the top end 416 of the conical member 404 .
[0048] The air stream within the conical member 404 is preferably in contact with a photocatalytic layer (not shown) coated on the interior surface of the conical member 404 . The photocatalytic layer is substantially similar to the one described earlier. In particular, the activated photocatalytic layer suitably oxidizes harmful organic molecules (VOCs) and destroys microbes in the air.
[0049] FIG. 5 illustrates a table lamp 500 incorporating the lighting device 400 . FIG. 6 illustrates a fixture structure 500 incorporating the lighting device 400 for replacing spot lamps. It is to be understood that the lighting device 100 of FIG. 1 would work equally as well in these two configurations.
[0050] FIG. 7 shows a linear lighting device 700 with an air purification feature. The linear lighting device 700 includes a housing 702 , a first set of LEDs 704 for general lighting applications at the bottom end 706 of the housing 702 , a second set of LEDs (not shown) inside the housing 702 for air purification, a plurality of inlet openings 708 near the bottom end 706 of the housing 702 for drawing in ambient air, at least one air outlet opening (not shown) running along the top end 710 of the housing 702 , a photocatalytic layer (not shown) on the inner surface of the housing 702 , and optical elements 712 along the bottom of the housing 702 for directing light from the first set of LEDs 704 . The linear lighting device 700 can replace linear fluorescent lighting fixtures, for example.
[0051] FIG. 8 shows the results obtained in a reactor containing a 405 nm light source and an uncoated test surface (direct), along with test surfaces coated with undoped (TiO 2 ) and nano-Ag doped titania coatings. In the closed reactor air containing initial 0.35 mmol/liter ethanol vapor was circulated, and the relative ethanol concentration was analyzed by means of gas chromatography and then plotted versus time.
[0052] The air flow needed to effectively purify the air when using blue wavelength is approximately 0.3 W@405 nm/m 3 . This value is also in line with a common practice of using 254 nm UV air purification (0.15 W/m 3 ).
[0053] The amount of time needed to cycle through all of the air in a typical conference, hotel, or hospital room is approximately three hours in a room having a height of three meters. Factors such as room temperature, artificial ventilation, and/or distance from ceiling may affect the overall performance of the device. With a constant light “ON” a significant reduction in pollutants is expected.
[0054] With reference to FIGS. 9-11 , the exemplary embodiment has been tested to confirm that the natural ventillation works. In particular, the temperature of the circuit board 102 of the lighting device 100 was first measured with the inlet holes 112 open. Next, the inlet holes 112 on the bottom were closed so that there was no convection on the fixture. When comparing the two results, it is evident that in case of the closed holes, the temperature is higher. See, for example, the graphs shown in FIG. 9 (15 W—larger enclosure), FIG. 10 (35 W—larger enclosure), and FIG. 11 (14 W—smaller enclosure). The shape of the device 100 may differ with respect to the diameters of the upper and lower sides, the height, however, is generally the same.
[0055] With reference now to FIG. 12 , a schematic view of an alternative lighting device 1200 is shown. The lighting device 1200 is generally similar in structure to the device 100 shown in FIG. 1 and operates in a similar manner. The differences between the lighting devices ( 100 , 1200 ) will be described in greater detail below. For example, the alternative lighting device 1200 includes an LED module 1202 removably thermally and electrically coupled to the bottom end 1204 of a housing or body 1206 , which generally acts as a chimney, inducing an upward flow of air in the lighting device 1200 . Generally, as shown in FIG. 12 , the body 1206 is conical in shape. However, other configurations may be implemented to the extent that they help to provide a chimney effect.
[0056] Suitably, one or more LEDs 1208 may be mounted on the lower surface of the module 1202 . The LEDs 1208 can be phosphor-coated LEDs, RGB LEDs, monochromatic LEDs, or a combination of phosphor and monochromatic LEDs. The light produced by the LEDs 1208 may be used for various types of lighting applications, including task lighting, accent lighting, general lighting and/or horticultural lighting. In addition, one or more optical elements may be included. The system may provide a minimum of 50 lumens and a maximum of 20000 lumens, but preferably between 600 and 10000 lumens.
[0057] The lighting device 1200 also includes one or more auxiliary LEDs (not shown) mounted on the upper side of a heat conductive layer 1209 on a mechanical holder 1210 for the module 1202 . The mechanical holder 1210 provides mechanical and electrical connection of the module 1202 to the housing 1206 . Generally, the LED module 1202 includes a thermal pad 1211 . The thermal pad 1211 provided with the module 1202 generally creates improved thermal connection with the heat conductive layer 1209 so as to increase the chimney effect. An example of an LED module for use in a lighting assembly is described, for example, in US Pub. No. 2011/0063849, the disclosure of which is incorporated herein by reference.
[0058] The auxiliary LEDs generally have an emission that is greater than 400 nm and is preferably at 405 nm (violet) or 450-460 nm (blue). In the case of a transparent conical member or in indirect lighting applications, the LEDs can be white LEDs with a high 405 nm component.
[0059] The housing 1206 typically includes at least one outlet opening 1212 at the upper end 1213 and a plurality of small openings (or apertures) 1214 spaced radially near the bottom end 1204 of the housing 1206 . For example, as shown in FIG. 12 , the small openings 1214 may be generally circular. However, other configurations may be implemented to the extent that they help to provide a chimney effect. For example, the small openings 1214 may comprise rectangular openings oriented diagonally around the bottom end of the conical member 404 .
[0060] As with the lighting device 100 of FIG. 1 , the LEDs of the alternative lighting device 1200 generate heat during operation. Ambient air is drawn in through the inlet openings 1214 . The heated air flows upwards and out through the opening 1212 at the top end 1213 of the housing 1206 .
[0061] The air stream within the housing 1206 is preferably in contact with a photocatalytic layer 1216 coated on the interior surface of the housing 1206 . The photocatalytic layer 1216 is substantially similar to the one described earlier. In particular, the activated photocatalytic layer suitably oxidizes harmful organic molecules (VOCs) and destroys microbes in the air.
[0062] The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | A lighting device combined with an air purification feature is disclosed. At least one function of the device is to provide high quality directional light for general lighting purposes. An additional function is to decompose VOCs and/or destroy microbes in the ambient air. The heat generated by white LEDs is utilized to generate air flow through the device. The geometry is designed to utilize the chimney effect and maximize volumetric flow. The circulated air is purified by a photocatalytic layer applied to the interior surface of the device. The lighting device can be built into pendant luminaires or lamps, thus ensuring vertical orientation of the light module. The exemplary embodiments may be applied in public places, hospitals, ward rooms, and other locations where a cost effective disinfection method is needed. | 5 |
This application is a continuation of 08/876,491 filed on Jun. 16, 1997 now U.S. Pat. No. 6,065,150.
BACKGROUND OF THE INVENTION
Common sports protective gloves such as those for hockey include a layer of foam rubber disposed in a back portion of the gloves for protecting the back of a hand, and protecting arm and fingers by means of a foam rubber layer. However, the thickness of the foam rubber layer is limited, and also its elasticity is limited, hardly effective to prevent harm or injury if the striking force is large. If the striking point is on the part where there is no foam rubber, the injury will be very serious.
SUMMARY OF THE INVENTION
Protective air cushion gloves according to the present invention have been devised with the following objects.
1. To offer protective gloves having air cushions functioning as buffer shock-absorbing means.
2. To offer protective gloves having excellent flexibility, a natural curvature for air cushions disposed in the gloves, with light weight and ease of handling.
3. To offer protective gloves having wholeness of air cushions disposed in the gloves, and extensible tubes added in each air cushion to permit the gloves to be very flexible to bend.
4. To offer protective gloves having buffer air cushions with flexible joints for completely protecting a hand.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will be better understood by referring to the accompanying drawings, wherein:
FIG. 1 is an elevational view of straight air cushions for finger backs arranged in rows for protective air cushion gloves according to the present invention;
FIG. 2 is an elevational view of a straight air cushion for a finger;
FIG. 3 is a right side view of FIG. 2;
FIG. 4 is a cross-sectional view taken along line 4 — 4 in FIG. 2;
FIG. 5 is an elevational view of an air cushion for the back of a hand back;
FIG. 6 is a right side view of FIG. 5;
FIG. 7 is a cross-sectional view taken along line 7 — 7 in FIG. 5;
FIG. 8 is an elevational view of the straight air cushion of FIG. 2, additionally provided with extensible tubes;
FIG. 9 is a cross-sectional view taken along line 9 — 9 in FIG. 8;
FIG. 10 is an elevational view of the air cushion for the back of a hand in FIG. 5, additionally provided with extensible tubes;
FIG. 11 is a cross-sectional view taken along line 11 — 11 in FIG. 10;
FIG. 12 is an elevational view of a straight air cushion provided with recessed holes in two surfaces according to the present invention;
FIG. 13 is a cross-sectional view taken along line 13 — 13 in FIG. 12;
FIG. 14 is an elevational view of a straight air cushion provided with through holes according to the present invention;
FIG. 15 is a cross-sectional view taken along line 15 — 15 in FIG. 14;
FIG. 16 is an elevational view of a first preferred embodiment of a single integral air cushion according to the present invention;
FIG. 17 is a cross-sectional view taken along line 17 — 17 in FIG. 16;
FIG. 18 is an elevational view of a second preferred embodiment of a single integral air cushion according to the present invention; and,
FIG. 19 is a cross-sectional view taken along line 19 — 19 in FIG. 18 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 16, hollow 3D air cushions disposed in protective air cushion gloves in the present invention are located in regular rows as shown in FIG. 1, or may be directly formed into single integral air cushion shown in FIG. 16 in a protective air cushion glove. Hollow 3D straight air cushions are divided into first straight air cushions 1 for protecting finger backs and second straight air cushions 10 for the back of a hand. The first straight air cushions 1 for finger backs have elongate grooves 11 in an upper surface or the upper surface and two sides, is providing the first straight air cushions 1 with flexibility. FIG. 4 shows its cross-sectional view.
The second straight air cushions 10 for a hand back are also provided with elongate grooves 101 in the upper surface, or the upper surface and two sides, or the upper surface, a lower surface and the two sides, permitting the second straight air cushions 10 to have flexibility. Its cross-section is shown in FIG. 7 .
Further, the lower end of each first hollow 3D straight air cushion 1 for a finger back may be provided with a sloped surface 12 , which can be utilized to face and hide an aperture when the lower end of a first straight air cushion 1 abuts a second straight air cushion 10 for a hand back.
Referring to FIGS. 8 and 10, the elongate grooves 11 , 101 shown in FIGS. 2 and 5 form extensible tubes 11 , 101 so as to obtain flexibility in various directions.
Referring to FIGS. 12 and 13, recessed holes 12 are additionally provided vertically in an upper surface and a lower surface or on two—left and right—sides of the first air cushions 1 for finger backs and the second air cushions 10 for a hand back shown in FIGS. 2 and 5. Then the first air cushions 1 and the second air cushions 10 are provided with a structure formed by the elongate grooves 11 and 101 and the recessed holes 12 functioning as post-shaped ribs so that comparatively high inner pressure may be filled inside. Besides, the recessed holes 12 and 102 may be formed only in one surface half through or wholly through as shown in FIGS. 14 and 15.
FIGS. 16 and 18 show that the first air cushion 1 and the second air cushions 10 are not disposed in a completely straight line. The extensible tubes 3 used to connect sections of each first air cushion 1 and sections of each second air cushion 10 with a common interior completely through, and not separated. Consequently, the single integrated air cushion has excellent flexibility owing to the extensible tubes 3 .
The single integrated air cushion shown in FIG. 18 has the extensible tubes 3 connecting sections of each first air cushion 1 and each second air cushion 10 , and in addition has recessed holes 12 and 102 in one surface or two surfaces, permitting the whole air cushions have flexibility and shape-memorable structure.
As to the extensible tubes 11 ′, 101 ′ and 3 , they can provide not only flexibility for bending, but also can be connected without apertures in the first and the second straight air cushions 1 and 10 so as to furnish complete protection.
Each straight air cushion 1 or 10 can be filled a gas, a fluid, a semi-fluid, a liquid, or a low-percolating large particle gas such as SF 6 , C 2 F 6 , etc.
In general, the protective air cushion gloves according to the present invention not only have better resilience than traditional ones made of sponge, or foam rubber, but also have an excellent shape-memorable structure obtained from the recessed holes and the elongate grooves so that the first and the second straight air cushions can be inflated to high inner pressure, and are not liable to disfigure. In addition, the recessed holes and the elongate grooves function as ribs so as to furnish the protective air cushion gloves with excellent flexibility, and shock-absorbing effect.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | Protective air cushion gloves include hollow 3D straight air cushions for finger backs and a hand back disposed in regular rows inside the glove. Each straight air cushion has sections connected with extensible tubes and inflated with inner pressure to permit the glove to have good flexibility and an air buffer function for protecting every part of a hand, including the joints. | 0 |
TECHNICAL FIELD
This invention relates to an apparatus for preparing a road bed, specifically the apparatus profiles the road surface, collects oversize material, crushes the oversize material and deposits the crushed material on the road bed.
BACKGROUND OF THE INVENTION
Preparation of road beds in mountainous rocky terrain is extremely expensive. Timber and undergrowth must be cleared and removed. Rock and other unwanted overburden must be removed. The contour of the surface must be prepared. Stone, sand or other underlayment must be trucked to the site, smoothed, profiled and compacted. Finally, the road surface, whether asphaltic compositions, concrete or rock, must be laid.
All of these various functions are performed by specialized equipment, such as bulldozers, pan scrapers, cranes, excavators, drag buckets and graders. Highly paid personnel are required to operate this equipment. The cost of the equipment, the cost to transport the equipment to and from the work site, and operators wages all add to the expense of preparing the road bed.
The greatest number of miles of these mountainous roads are not paved for passenger car usage, but have a crushed rock surface and are used for access to timber harvesting sites, power line maintenance roads, fire prevention access roads and pipe line maintenance roads. The cost of the timber harvested and power and gas transmission costs are directly related to the cost of the roads necessary to secure, maintain or transport that resource.
One of the major expenses in preparing a road bed in rocky terrain is the removal of rock which is oversize for the bed surface and replacement of this rock material with properly sized rock. Currently, the least expensive method of road construction is to remove the oversize rock and deposit the rock in fill areas or in a waste tailing area. Properly sized crushed rock is then purchased from a supplier and trucked to the site as needed. An alternative is to temporarily erect a rock crushing machine in an area near the road work, carry the rock to this area, crush the rock and then transport the crushed rock back to the road bed. This approach reduces the transportation cost and eliminates the need to purchase crushed rock, but requires preparation of a site to erect the crushing apparatus which adds to the cost of preparing the road. Also, this alternative is often not practical because of the topography of the terrain and the unavailability of specialized rock crushing equipment.
It is, therefore, an object of this invention to provide an apparatus which can assist in preparing a road bed by crushing rock at the road building site.
It is a further object of the invention to have a self-propelled apparatus which loads and crushes rock without the need of additional equipment.
It is also an object of the invention to provide an apparatus which can perform excavating and road surface profiling.
A further object is to provide an apparatus wherein multiple road working functions ca be performed by a single operator from a single operating position.
Another object of the invention is to provide a road bed preparation device which can operate on unimproved surfaces.
Other objects and advantages of the present invention will be apparent from the following description of a preferred embodiment thereof and from the attached drawings.
DISCLOSURE OF THE INVENTION
The only practical way to reduce the cost of building a road bed is to reduce the amount of equipment and the number of equipment operators necessary to prepare the road bed. This invention solves this problem by providing a self-propelled apparatus to perform a plurality of functions necessary to prepare a road bed. An internal combustion engine drives a plurality of hydraulic pumps. A hydraulically driven pair of tracked drives are used to support, propel and steer the apparatus. A frame interconnects the drive tracks and the other components of the apparatus.
A scoop is interconnected to the frame by a pair of push arms. Fluid cylinders control the angle of attack of the scoop, the tilt and the rotation of the scoop. The scoop profiles the road surface by cutting away overburden and unwanted earth and rock. The scoop also collects the overburden. A conveyor transports the overburden from the scoop to a crusher. The crusher reduces the size of the rock to a size acceptable for depositing on the road bed.
An articulated bucket assembly having a boom, an arm, and a bucket is located on the frame. The bucket assembly is used to excavate the overburden and to deposit the material in the scoop. A thumb is mounted on the arm to work in conjunction with the bucket to lift or move oversize material.
The apparatus can prepare a road surface by excavating material, profiling the road surface, crushing rock in situ, and placing the crushed rock back on the road bed.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the apparatus for preparing a road surface of the present invention.
FIG. 2 is a front view of the apparatus for preparing a road surface of the present invention.
FIG. 3 is a side view of the scoop and push arm of the present invention, showing the range of lift and rotation of the scoop.
FIG. 4 is a schematic front view of the scoop of the present invention, showing the range of tilt of the scoop.
FIG. 5 is a partial, broken-away sectional side view of the apparatus to prepare a road surface of the present invention, taken along lines 5--5 of FIG. 2 and showing a first embodiment of a means to convey material.
FIG. 6 is a partial, broken-away sectional side view of the apparatus to prepare a road surface of the present invention, taken along lines 5--5 of FIG. 2 and showing a second embodiment of a means to convey material.
FIG. 7A is a perspective view of the conveyor support arms of the FIG. 6 embodiment of the present invention, and
FIG. 7B is an enlarged perspective view of the encircled portion of FIG. 7A.
FIG. 8 is a cross-section of the slip joint of a conveyor support arm of the present invention, taken along lines 8--8 of FIG. 7A.
FIG. 9 is a cross-section of the spherical ball connector of the end of a conveyor support arm of the present invention, taken along lines 9--9 of FIG. 7B.
FIG. 10 is a partial perspective view of a portion of the conveyor support arm of the FIG. 6 embodiment of the conveyor, having conveyor support rollers attached thereto.
FIG. 11 is an enlarged partial exploded view of the conveyor belt, a drive chain, and a conveyor flight of the FIG. 6 embodiment of the invention.
FIG. 12 is a partial perspective view of the material separator of the FIG. 5 and FIG. 6 embodiments of the present invention.
FIG. 13 is an enlarged partial side cross-section of the rock crusher of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 and FIG. 2, a frame 2 interconnects all of the components of the apparatus to prepare a road surface. The frame 2, in the preferred embodiment, is manufactured of structural steel members having bracketry and other elements attached thereon to connect all of the components of a multi-purpose machine to prepare a road surface. The apparatus is driven by an internal combustion engine 4 mounted on the frame 2. The engine 4 typically is a 195 SAE horsepower turbocharged diesel engine. The diesel engine 4 has three open center pumps (not shown) mounted in line and coupled directly to the flywheel of the engine 4. The total flow of the hydraulic pumps is typically 175 gallons per minute per pump at rated engine rpm. One of the pumps is used to propel the apparatus and has an operating pressure of approximately 2,800 pounds per square inch. The remaining two pumps have a rated pressure of approximately 2,700 pounds per square inch and drive the other components of the apparatus.
A pair of tracked undercarriages 6 and 6' are used for propulsion of the apparatus. The tracked undercarriages 6 and 6' allow the apparatus to be used on unimproved terrain. The tracked undercarriages are similar to the undercarriages used on bulldozers, excavators and crane devices. Each of the tracked undercarriages has a track undercarriage frame 8. Each track frame 8 is a formed reinforced U-channel section. The track frame is rigidly mounted to the frame 2 of the apparatus. The tracks 6 and 6' are each driven by a high torque, axial piston, variable speed hydraulic motor 10, with planetary drives. There is one motor per track. Multiple disc brakes automatically release while the apparatus is being propelled and apply when the apparatus is stationary. Independent drive to each track undercarriage permits counter-rotation and, therefore, steering of the apparatus. Each track undercarriage assembly 6 is supported on the track undercarriage frame 8 by nine lower rollers 12 and two upper rollers 14.
A push bar 16 having a first end and a second end is connected at its first end to the undercarriage frame 8 by means of a spherical ball joint 18. The push bar 16 is attached at its second end to a bucket 20 by means of a similar spherical ball joint assembly 22. Spherical ball joint assemblies 18 and 22 allow the push bar 16 to move up and down about the fixed pivot point on the undercarriage frame 8 and also allows a limited amount of axial rotation of the scoop 20.
Scoop 20 has a replaceable leading edge 24. This leading edge 24, in one embodiment, has a smooth cutting surface. Alternate embodiments may have various attachments, such as rock guards 25 as shown in FIG. 1. The scoop acts to remove overburden or unwanted material from the road surface, much like a bulldozer. An alternate embodiment of the leading edge may have chip breakers to tear up existing asphaltic pavements.
The upper portion of scoop 20 has a deflector 26 mounted on the upper portion thereof to prevent material larger than a predetermined diameter from entering the scoop. In a preferred embodiment, deflector 26 is attached approximately 36 inches above the replaceable cutting edge 24. Thus, the deflector 26 will push to the side any rock or other material with a diameter greater than 36 inches. In an alternate embodiment, this deflector can be set 24 inches above the cutting edge 24 to exclude any material having a diameter greater than 24 inches.
A pair of lift cylinders 30 and 30', each having a first end and a second end, are attached on their first end on each side of the apparatus to the frame 2 and on their second end to push bar 16. These lift cylinders can be operated independently and can adjust the lift of the push bar and, hence, the height of the scoop 20. A second pair of hydraulic cylinders 32 and 32', each having a first end and a second end, have their first end attached to a bracket attached to the push arm 16 and the second end attached to the scoop 20. This allows the scoop to be rotated about the spherical ball joint 22 of push bar 16. The range of motions and the various actions caused by the first pair of lift cylinders 30 and the second pair of rotational cylinders 32 will be explained below.
An excavator bucket assembly 34 is mounted on frame 2. The excavator bucket assembly is used to remove overburden not accessible to scoop 20. The bucket assembly has a boom 36, an arm 38, and a bucket 40. The boom 36 is controlled by a pair of hydraulic cylinders 42 and 42'. Hydraulic cylinders 42 and 42' allow the boom 36 to be rotated about a pivot point 44. The hydraulic cylinders 42 and 42' lift and lower the boom 36. A hydraulic cylinder 46 has its first end attached to the boom 36 and its second end attached to the arm 38. This allows the arm 38 to be rotated about pivot point 48 to raise and lower the arm 38 relative to the boom 36. A hydraulic cylinder 50 is attached to the arm 38 and attached through suitable linkage to the bucket 40. Actuation of hydraulic cylinder 50 allows the bucket 40 to be rotated in respect to the arm 38 about pivot point 52. A thumb 54 is pivotally attached to the arm 38. A hydraulic cylinder 56 allows the thumb to be rotated about pivot point 58 on arm 38. The thumb 54 can cooperate with the bucket 40 to grasp large objects and either place them into the scoop 20 or remove them out of the way of the scoop 20.
Bucket assembly 34 can be used to excavate an overlying area to the side of the apparatus as, for instance, when profiling a hillside and to take the material removed and place it into the scoop 20. Similarly, bucket assembly 34 can be used to excavate a trench below the level of the apparatus and to lift the material into the scoop 20.
A control cab 59 is attached to frame 2 above one of the pairs of tracks 6. This allows an operator a clear view of the bucket assembly 34, the scoop 20 and the other components of the apparatus.
Referring now to FIG. 2, two additional hydraulic cylinders 60 and 60' have their first ends attached to the frame 2 and their second ends attached to the bucket assembly 34. Actuation of cylinders 60 and 60' allow the bucket assembly 34 to be rotated from side-to-side.
As can be seen in FIG. 2, scoop assembly 20 has upward sloping bottom section 62 and inward sloping side sections 64. This arrangement allows any material collected by the scoop to be forced toward the center portion of the scoop and be collected by a conveyor system 66. The details of conveyor system 66 will be explained below.
Referring now to FIG. 3, it can be seen how hydraulic cylinder 30, when activated, can raise scoop assembly 20 to the position shown by the broken lines of FIG. 3. As cylinder 30 is operated, push arm 16 rotates about the spherical ball joint 18 which is located on the undercarriage frame 8 (not shown). Similarly, hydraulic cylinder 32, when activated, can tilt or rotate the scoop assembly 20 about the spherical ball joint 22.
FIG. 4 is a representation of the scoop assembly 20, as one hydraulic cylinder 30 is operated in relationship to the second hydraulic cylinder 30'. This allows the scoop assembly 20 to be rotated about a longitudinal axis in order to cut the road surface at an angle.
Referring now to FIG. 5, a partial cross-sectional view of the apparatus to prepare the road surface is shown with a rock crusher 68 attached to the frame 2. This sectional view is taken along lines 5--5 of FIG. 2 and the bucket assembly 34 has been removed for clarity. A first embodiment of the conveying system 66 for conveying the material collector by the scoop 20 to the rock crusher 68 is shown in FIG. 5. A conveyor 70 has a first end pivoted about pivot point 72. Pivot point 72 lies along the line formed by the intersection of spherical ball joint 22 and corresponding spherical ball joint 22'. The second end of conveyor 70 is pivoted about a pivot point 74 which is in line with the spherical ball joint 18 and 18'. In this manner, as the scoop assembly 20 is raised and lowered and pivoted, the length of conveyor 70 does not change. Conveyor 70 is driven by a hydraulic motor driving conveyor 70 about pivot point 74.
A second conveyor 76 is used to lift the material from conveyor 70 to a grizzly 78. Grizzly 78 is used to separate fine material from the large rock, prior to the rock being deposited in rock crusher 68. Because the lift of conveyor 76 is so steep, rather substantial flights 80 are required on the conveyor 76 to lift the rock up to the grizzly. Conveyor 76 is of a fixed length, having a pivot point 82 lying below the pivot point 74 of conveyor 70. Clearance must be provided between pivot point 74 and pivot point 82 to allow the flights 80 to clear conveyor 70. The second pivot point 84 of conveyor 76 drives the conveyor by means of an additional hydraulic motor (not shown). Sheet metal guides 86 and 88 are located on each side of conveyor 70 to ensure that the material being conveyed by conveyor 70 does not fall to the sides of the conveyor. A similar sheet metal guide 90 is located adjacent conveyor 76, again to prevent the material from falling to the sides of the conveyor. One aspect of this embodiment of the conveyor system is that the lift required by conveyor 76 is rather steep. The opening between conveyor 70 and conveyor 76, that is, between the pivot point 82 and 74, is sufficiently large to allow fine material to fall between the conveyors.
A second embodiment of the conveyor system can be seen in FIG. 6. In this, the preferred embodiment of the conveyor system, the conveyor 92 is supported by a pair of parallel arm assemblies 93 and 93', as shown in FIG. 7A. The first parallel arm assembly 93 has an upper arm 94, a lower arm 95 and a slip joint 96. Similarly the second parallel arm assembly 93' has an upper arm 94', a lower arm 95' and a slip joint 96'. The upper arms 94 and 94' and the lower arms 95 and 95' may be solid as shown in FIG. 8 or may be heavy wall rectangular tubing. The slip joints 96 and 96' are heavy wall hollow numbers having inside dimensions slightly larger than the outside dimensions of arms 94, 94', 95, and 95'. Slip joint 96 is welded to either upper arm 94 or lower arm 95 with the other arm free to slide within the slip joint 96. Slip joint 96' is attached in a similar manner. In the embodiment shown in FIG. 7A, the slip joint 96 is welded to the lower arm 95 and slip joint 96' is welded to lower arm 95'.
Each upper arm 94, 94' and each lower arm 95, 95' has a spherical ball joint 110 welded on the end opposite the slip joint 96. These spherical ball joints 110 allow each arm assembly 93, 93' free rotational movement about the attachment point plus allows each arm assembly a limited rotational movement along their respective centerlines. FIG. 9 shows a cross section of spherical ball joint 110. A spherical ball 112 is restrained in a housing 114. It can be seen in FIG. 9 how the spherical ball 112 can rotate within housing 114. It can also be seen how the ball 112 may rotate to the left or the right in FIG. 9 to allow a limited amount of rotation along the centerline of the arm assemblies 93 and 93'.
Referring back to FIG. 6 it can be seen that spherical ball joint 110 attached to lower arm 95 is attached to pivot point 72. Pivot point 72 is in line with spherical ball joints 22 of scoop 20. The spherical ball joint 110 attached to upper arm 94 is attached at pivot point 84 which is on the frame 2 near the entrance of grizzly 78. This arrangement of attachment points allows the conveyor to make a shallow angle with the ground level. Typically this angle is less than 30° and more particularly about 20°. The conveyor 92 need only lift the overburden approximately 5-6 feet from the scoop 20 to the rock crusher 70. As scoop 20 is raised arm assembly 93 may shorten and as scoop 20 is lowered arm assembly 93 may lengthen. Similarly, as the scoop is rotated as shown in FIG. 4, one arm assembly may contract and the other arm assembly may expand. Each arm assembly 93, 93' may also rotate about its longitudinal axis to compensate for this rotation of scoop 20.
Because the length of the arm assemblies 93, 93' may vary in length, an apparatus consisting of a bell crank arm 100 with pressure roller 102 is provided to maintain the tension in conveyor belt 92. The bell crank arm has a spring 104 which maintains a preset force on roller 102 to maintain the tension in conveyor belt 92. It would be obvious to one skilled in the art that alternate methods of tensioning the conveyor are possible which lie within the scope and spirit of the above disclosure.
Referring now to FIG. 10, it can be seen how the conveyor belting material is supported by the parallel arm assemblies 93 and 93'. A roller 106, attached to a shaft 120, is supported in spherical ball bearings 122 attached to each arm assembly. Only the upper arms 94 and 94' are shown in FIG. 10 but it is understood that similar structures may be attached to arms 95 and 95'. The ladder support arms 94 and 94' are spaced apart approximately 36 inches. The roller 106 is typically 24 inches long and is centered between the arms 94 and 94'. The spherical ball joints 122 allows each arm 94 and 94' to be raised or lowered independently of the other arm and allows the arm to rack independently. One of the advantages of the second embodiment of the conveyor system is that the sides of the conveyor belt can be bent upwardly at up to 45 degrees from the horizontal as the conveyor progresses up the arm assemblies 93 and 93'. This is accomplished by rollers 124 attached to an angle bracket 126. Angle bracket 126 is rigidly attached to the ladder support arm 94. Referring back to FIG. 6, it can be seen how the conveyor material is folded by obscuring the outline of conveyor material 130. In a preferred embodiment of this conveyor system, the total conveyor width is approximately 6 feet. The scoop is approximately 10 feet, 6 inches wide at its opening and the side deflector panel 64 narrows this to approximately 6 feet wide at the scoop opening. At the midpoint length of arm assemblies 93 and 93', the bottom width of the conveyor is approximately 36 inches, with 18 inches on each side being folded up at approximately a 45 degree angle. In this manner, relative short flights are required to lift the material up the conveyor, and side deflector pieces 88 and 90 shown in FIG. 5 are not needed.
Referring now to FIG. 11, the flights 108 are attached through the conveyor belting 130 to a conveyor drive chain 134. A suitable threaded fastener 136 securely attaches the flight 108 to the conveyor chain 134 by engaging a mating nut 138. Drive chain 134 is on each side of the conveyor 92 and is approximately 3 feet between each attachment point 136. In this manner, the height of the flight 108 need only be approximately 4 inches tall. The conveyor belting 130 is made of conventional fabric reinforced rubberized material, as is known in the art. The drive chain 134 is a conventional roller-type chain. The drive chain 134 engages a sprocket (not shown) which lies on the pivot point 84 of FIG. 6. This sprocket is driven by hydraulic motor (not shown).
The grizzly 78 as shown in FIG. 12 is a static device used to separate material by size. The grizzly 78 comprises a framework 140 supporting a series of rods 142. The rods 142 are spaced apart, such that fine material falls between the rods, but the larger material is transported across the rods. The rods 142 are arranged in parallel relationship in the direction of travel of the material. In preparing a road surface in which a considerable amount of dirt and other fine material is mixed with the rock to be crushed, the grizzly provides a convenient method to divert the dirt from the rock crusher. In this manner, only oversized rock material is supplied to the rock crusher to be reduced in size. In the preferred embodiment, the spacing between the rods 142 is approximately 11/2 inches. A simple metal piece may cover the grizzly if the grizzly is not needed.
The rock crusher 68 is a single jaw crusher, as shown in FIG. 13. The rock crusher 68 may be a Model 48-36 single jaw crusher, manufactured by Kobe Steel Limited of Tokyo, Japan. This crusher has an opening at the top that is 48 inches wide and 36 inches long. In this manner, a 36 inch diameter rock can easily be reduced in size. The exit opening of the rock crusher is adjustable, such that the rock is reduced in size to a predetermined amount. In the preferred embodiment, this size will be approximately 2 inches in diameter or smaller.
A hydraulic motor (not shown) drives a flywheel 150 on the rock crusher 68. The flywheel 150 drives an eccentric 152. Attached to the eccentric is a movable jaw 154. Movable jaw 154 has a replaceable shoe 156 attached at the operating side thereof. A stationary shoe 158 is located on the opposite side of the rock crusher from the movable shoe. A replaceable fix jaw 160 is attached to the fixed shoe.
As the eccentric 152 is rotated, the movable jaw 156 moves toward the fixed jaw 160. A lower toggle 162 is attached to the lower end of the movable jaw 154. This toggle has a toggle seat 164 against which presses a smaller diameter safety toggle 166. The safety toggle 166 is designed in such a manner that, should an overload occur, it will shear, allowing the lower end of the movable jaw 154 to move away from the fixed jaw 160, preventing damage to the crusher. The safety toggle has a seat 168 which is adjustable by a hydraulic cylinder 170. The hydraulic cylinder 170 adjusts the lower jaw opening "D" to adjust the exit size of the rock being crushed. A spring tensioning device 172 keeps the lower end of the movable jaw 154 in proper alignment during operation.
Summary of Operation
As can be seen in the above-detailed description of a preferred embodiment, this apparatus replaces several conventional pieces of road equipment. The apparatus performs the function of a bulldozer in profiling the road surfaces immediately in front of the apparatus. The apparatus functions as an excavator in removing overburden above or below the grade level on each side of the apparatus. The apparatus also acts as a crane in removing oversize material from in front of the excavator.
The apparatus is especially well suited for road work in hilly or mountainous terrain. The mounting of the rock crusher and engine low in the chassis gives the apparatus a very low center of gravity and hence a high degree of stability. The mounting of the conveyor low and central in the chassis also aids the stability of the apparatus. Rock and overburden only needs to be lifted approximately five feet from the scoop to the grizzly and rock crusher. Thus an increase in the amount of rock will not raise the center of gravity appreciably and therefore not upset the stability of the apparatus.
The low placement of the rock crusher also has the advantage of placing the discharge side of the rock crusher close to the road surface. The crushed rock need only fall approximately one foot. This prevents the rock from scattering and presents a uniform four foot wide deposit of crushed rock. The low discharge also prevents the crushed rock from bouncing into the tracks of the vehicle.
The construction of the push bar and scoop allows the apparatus to profile cut the earth surface much like a bulldozer. Compacted material such as gravel, clay, sand and dirt along with embedded rocks may be cut away from the proposed road bed with the cutting edge of the scoop. Loose rocks and boulders as large as thirty six inches in diameter are accepted by the scoop. The scoop and hence the leading cutting edge can be angled from side to side to profile the road surface at an angle. The material thus cut away can be conveyed up the conveyor to the grizzly where the fine material can be separated from the more course material. The larger material is thus reduced in size by the rock crusher and redeposited on the road surface.
The apparatus may also function as a front end loader. In this operating mode, the conveyor is stopped. Overburden, rock or unwanted material is collected in the scoop. The scoop is raised and the vehicle is moved to the location where the unwanted material is to be deposited. The scoop is rotated so that the cutting edge is lowered, thus depositing the material.
Organic material such as tree stumps is not desirable in a road bed underlayment. Usually all stumps and other organic material are removed before road work begins. The present apparatus can remove small stumps and logs with the articulated bucket assembly. The bucket assembly and the scoop in conjunction with one another can uproot small stumps and the bucket assembly can lift these stumps out of the path of the present apparatus.
Another especially beneficial use of the present apparatus is in renewing asphaltic road surfaces. Generally the old road surface must be broken up and hauled away. This necessitates laying a new base for the new pavement. Because the rock crusher is adjustable on its output side for size, it may be set to produce crushed old asphalt pavement fine enough for the new base. Chipper, breaker type teeth are mounted on the leading edge of the scoop. The scoop simultaneously rips and breaks up the old road surface into pieces small enough to be conveyed to the rock crusher. The rock crusher reduces the size of the old pavement small enough to be used as underlayment for the new road surface.
Of course, it should be understood that a wide range of changes and modifications can be made to the preferred embodiment described above. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, which is intended to define the scope of the invention. | A multi-purpose apparatus to prepare a road surface is disclosed. The apparatus includes a scoop which cuts, profiles and collects material. A conveyor connected to the scoop transports the material from the scoop to a rock crusher. The rock crusher reduces the size of the rock and deposits the crushed rock back on the road bed. An articulated bucket assembly is mounted on the apparatus to excavate overburden and to deposit the overburden into the scoop. | 4 |
This application is a continuation-in-part of Mandeville et al., U.S. Ser. No. 08/071,564 filed June 2, 1993 entitled "Process for Removing Bile Salts from a Patient and Compositions Therefor," and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to removing bile salts from a patient.
Sequestering and removing bile salts (e.g., cholate, glycocholate, glycochenocholate, taurocholate, and deoxycholate salts) in a patient can be used to reduce the patient's cholesterol level. Ion exchange resins which, when ingested, remove bile salts via the digestive tract, have been used for this purpose. Removal of bile salts will cause the body to prepare more bile salts. Because the biological precursor to bile salt is cholesterol, the metabolism of cholesterol to make bile salts is accompanied by a simultaneous reduction in the cholesterol in the patient.
SUMMARY OF THE INVENTION
In a first aspect, the invention features a method of removing bile salts from a patient by ion exchange that includes administering to the patient a therapeutically effective amount of one or more highly crosslinked polymers that are non-toxic and stable once ingested. The polymers are characterized by a repeat unit having the formula ##STR4## or copolymer thereof, where n is an integer; R 1 is H or a C 1 -C 8 alkyl group (which may be straight chain or branched, substituted or unsubstituted, e.g., methyl); M is ##STR5## or --Z--R 2 ; Z is O, NR 3 S or (CH 2 ) m ; m=0-10; R 3 is H or a C 1 -C 8 alkyl group (which may be straight chain or branched, substituted or unsubstituted, e.g., methyl); and R 2 is ##STR6## where p=0-10, and each R 4 , R 5 , and R 6 , independently, is H, a C1-C 8 alkyl group (which may be straight chain or branched, substituted or unsubstituted, e.g., methyl), or an aryl group (e.g., having one or more rings and which may be substituted or unsubstituted, e.g., phenyl, naphthyl, imidazolyl, or pyridyl).
By "non-toxic" it is meant that when ingested in therapeutically effective amounts neither the polymers nor any ions released into the body upon ion exchange are harmful. Preferably, the ions released into the body are actually beneficial to the patient. Such is the case when, for example, the exchangeable ions are natural nutrients such as amino acids.
By "stable" it is meant that when ingested in therapeutically effective amounts the polymers do not dissolve or otherwise decompose to form potentially harmful by-products, and remain substantially intact so that they can transport ions following ion exchange out of the body.
In preferred embodiments, the polymer is crosslinked by means of a multifunctional crosslinking co-monomer, the co-monomer being present in an amount from about 1-25% (more preferably about 2.5-20%) by weight, based upon total monomer weight.
The polymer further preferably includes one or more hydrophobic co-monomers, e.g., styrene, vinyl naphthalene, ethyl vinylbenzene, N-alkyl and N-aryl derivatives of acrylamide and methacrylamide, alkyl and aryl acrylates, alkyl and aryl methacrylates, 4-vinylbiphenyl, 4-vinylanisole, 4-aminostyrene, and fluorinated derivatives of any of these co-monomers (e.g., p-fluorostyrene, pentafluorostyrene, hexafluoroisopropylacrylate, hexafluorobutylmethacrylate, or heptadecafluorodecylmethacrylate). The alkyl groups are preferably C 1 -C 15 alkyl groups, and may be straight chain, branched, or cyclic (e.g., cyclohexyl), and may further be substituted or unsubstituted. The aryl groups preferably have one or more rings and may be substituted or unsubstituted, e.g., phenyl, naphthyl, imidazolyl, or pyridyl. The polymer may also include one or more positively charged co-monomers, e.g., vinyl pyridine, dimethylaminomethyl styrene, or vinyl imidazole.
One example of a preferred polymer is characterized by a repeat unit having the formula ##STR7## or copolymer thereof. The polymer may further include, as a co-monomer, one or more of the following: n-butylmethacrylamide, hexafluorobutylmethacrylate, heptadecafluorodecylmethacrylate, styrene or fluorinated derivatives thereof, 2-vinyl naphthalene, 4-vinyl imidazole, vinyl pyridine, trimethylammoniumethylmethacrylate, trimethylammoniumethylacrylate, 4-vinylbiphenyl, 4-vinylanisole, or 4-aminostyrene.
A second example of a preferred polymer is characterized by a repeat unit having the formula ##STR8## or copolymer thereof. The polymer may also include, as a co-monomer, one or more of the following: isopropylacrylamide, styrene or fluorinated derivatives thereof, hexafluoroisopropylacrylate, and trimethylammoniumethylmethacrylate.
A third example of a preferred polymer is characterized by a repeat unit having the formula ##STR9## or copolymer thereof. The polymer may also include, as a co-monomer, styrene or a fluorinated derivative thereof.
A fourth example of a preferred polymer is characterized by a repeat unit having the formula ##STR10## or copolymer thereof.
A fifth example of a preferred polymer is characterized by a repeat unit having the formula ##STR11## or copolymer thereof.
A sixth example of a preferred polymer is characterized by a repeat unit having the formula ##STR12## or copolymer thereof. The polymer may further include, as a co-monomer, ethyl vinylbenzene.
A seventh example of a preferred polymer is characterized by a repeat unit having the formula ##STR13## or copolymer thereof.
An eighth example of a preferred polymer is characterized by a repeat unit having the formula ##STR14## or copolymer thereof. The polymer may also include, as a co-monomer, styrene or a fluorinated derivative thereof.
In a second aspect, the invention features a method for removing bile salts from a patient by ion exchange that includes administering to the patient a therapeutically effective amount of one or more highly crosslinked polymers characterized by a repeat unit having the formula ##STR15## or copolymer thereof, where n is an integer; R 1 is H or a C 1 -C 8 alkyl group; L is --NH-- or G is ##STR16## and each R 2 , R 3 , and R 4 , independently, is H, a C 1 -C 8 alkyl group, or an aryl group. The polymers are non-toxic and stable once ingested.
In preferred embodiments, the polymer is crosslinked by means of a multifunctional crosslinking co-monomer which is present in an amount from about 1-25% by weight (and preferably from about 2.5-20% by weight), based upon total monomer weight. The polymer further preferably includes one or more of the above-described hydrophobic co-monomers
One example of a preferred polymer is characterized by a repeat unit having the formula ##STR17## or copolymer thereof. The polymer may further include, as a co-monomer, styrene or a fluorinated derivative thereof.
A second example of a preferred polymer is characterized by a repeat unit having the formula ##STR18## or copolymer thereof.
The polymers according to the first and second aspects of the invention may have fixed positive charges, or may have the capability of becoming charged upon ingestion at physiological pH. In the latter case, the charged ions also pick up negatively charged counterions upon ingestion that can be exchanged with bile salts. In the case of polymers having fixed positive charges, however, the polymer may be provided with one or more exchangeable counterions. Examples of suitable counterions include Cl - , Br - , CH 3 OSO 3 - , HSO 4 - , SO 4 2- , HCO 3 , CO 3 - , acetate lactate succinate, propionate, butyrate, ascorbate, citrate, maleate, folate, an amino acid derivative, a nucleotide, a lipid, or a phospholipid. The counterions may be the same as, or different from, each other. For example, the polymer may contain two different types of counterions, both of which are exchanged for the bile salts being removed. More than one polymer, each having different counterions associated with the fixed charges, may be administered as well.
The invention also features therapeutic compositions for removing bile salts that include a therapeutically effective amount of one or more of the above-described polymers.
In another aspect, the invention features a highly crosslinked polymer composition that includes a polymer characterized by a repeat unit having the formula ##STR19## where R 1 is H or methyl, Q is --NH--(CH 2 ) 3 -- or --O--(CH 2 ) 2 and n is an integer, and at least one additional co-monomer selected from the group consisting essentially of vinylnaphthalene, vinylimidazole, fluorinated derivatives of styrene, and fluorinated alkyl methacrylates.
In some preferred embodiments of this aspect, R 1 is methyl and Q is --NH--(CH 2 ) 3 --. This polymer may further comprise, as a co-monomer, trimethylammoniumethylacrylate or trimethylammoniumethylmethacrylate. In other preferred embodiments, Q is --O--(CH 2 ) 2 .
Examples of suitable fluorinated styrene derivatives include p-fluorostyrene and pentafluorostyrene. Examples of suitable fluorinated alkyl methacrylates include hexafluorobutyl methacrylate and heptadecafluorodecyl methacrylate.
In yet another aspect, the invention features a highly crosslinked polymer composition that includes a polymer characterized by a repeat unit having the formula ##STR20## where R 1 is H or methyl, Q is --NH--(CH 2 ) 3 --or --O--(CH 2 ) 2 and n is an integer, and, as additional co-monomers, (a) styrene and (b) trimethylammoniumethylacrylate or trimethylammoniumethylmethacrylate when R 1 is methyl and Q is --NH--(CH 2 ) 3 --
In an additional aspect, the invention features a method of synthesizing a highly crosslinked polymer having hydrophilic and hydrophobic units that includes reacting hydrophilic and hydrophobic monomers in the presence of an alcoholic solvent.
In yet another aspect, the invention features a method for removing bile salts from a patient that includes administering to the patient a therapeutically effective amount of the reaction product of:
(a) one or more highly crosslinked polymers characterized by a repeat unit having the formula: ##STR21## and salts and copolymers thereof, where n and m are integers and each R 1 , R 2 , and R 3 , independently, is H or a C 1 -C 8 alkyl group; and
(b) at least one alkylating agent, The reaction product is non-toxic and stable once ingested.
By "salt" it is meant that the amine nitrogen group in the repeat unit is protonated to create a positively charged nitrogen atom associated with a negatively charged counterion.
By "alkylating agent" it is meant a reactant which, when reacted with the crosslinked polymer, causes an alkyl group or derivative thereof (e.g., an aralkyl, hydroxyalkyl, alkylammonium salt, alkylamide, or combination thereof) to be covalently bound to one or more of the nitrogen atoms of the polymer.
In preferred embodiments, the reaction product is crosslinked by means of a multifunctional crosslinking co-monomer, the co-monomer being present in an amount from about 1-25% (more preferably about 2.5-20%) by weight, based upon total weight monomer weight.
One example of a preferred polymer is characterized by a repeat unit having the formula ##STR22## or a salt or copolymer thereof.
A second example of a preferred polymer is characterized by a repeat unit having the formula ##STR23## or a salt or copolymer thereof.
Preferred alkylating agents have the formula RX where R is a C 1 -C 20 alkyl, C 1 -C 20 hydroxyalkyl, C 1 -C 20 aralkyl, C 1 -C 20 alkylammonium, or C 1 -C 20 alkylamido group and X includes one or more electrophilic leaving groups. By "electrophilic leaving group" it is meant a group which is displaced by a nitrogen atom in the crosslinked polymer during the alkylation reaction. Examples of preferred leaving groups include halide, epoxy, tosylate, and mesylate group. In the case of, e.g., epoxy groups, the alkylation reaction causes opening of the three-membered epoxy ring.
Examples of preferred alkylating agents include a C 1 -C 20 alkyl halide (e.g., an n-butyl halide, n-hexyl halide, n-octyl halide, n-decyl halide, n-dodecyl halide, n-tetradecyl halide, n-octadecyl halide, and combinations thereof); a C 1 -C 20 dihaloalkane (e.g., a 1,10-dihalodecane); a C 1 -C 20 hydroxyalkyl halide (e.g., an 11-halo-l-undecanol); a C 1 -C 20 aralkyl halide (e.g., a benzyl halide); a C 1 -C 20 alkyl halide ammonium salt (e.g., a (4-halobutyl) trimethylammonium salt, (6-halohexyl) trimethylammonium salt, (8-halooctyl)trimethylammonium salt, (10-halodecyl) trimethylammonium salt, (12-halododecyl) trimethylammonium salts and combinations thereof); a C 1 -C 20 alkyl epoxy ammonium salt (e.g., a (glycidylpropyl)trimethylammonium salt); and a C 1 -C 20 epoxy alkylamide (e.g., an N-(2,3-epoxypropane) butyramide, N-(2,3-epoxypropane) hexanamide, and combinations thereof).
It is particularly preferred to react the polymer with at least two alkylating agents. In one preferred example, one of the alkylating agents has the formula RX where R is a C 1 -C 20 alkyl group and X includes one or more electrophilic leaving groups (e.g., an alkyl halide), and the other alkylating agent has the formula R'X where R' is a C 1 -C 20 alkyl ammonium group and X includes one or more electrophilic leaving groups (e.g., an alkyl halide ammonium salt).
In another preferred example, one of the alkylating agents has the formula RX where R is a C 1 -C 20 alkyl group and X includes one or more electrophilic leaving groups (e.g., an alkyl halide), and the other alkylating agent has the formula R'X where R' is a C 1 -C 20 hydroxyalkyl group and X includes one or more electrophilic leaving groups (e.g., a hydroxy alkyl halide).
In another preferred example, one of the alkylating agents is a C 1 -C 20 dihaloalkane and the other alkylating agent is a C 1 -C 20 alkylammonium salt.
The invention provides an effective treatment for removing bile salts from a patient (and thereby reducing the patient's cholesterol level). The compositions are nontoxic and stable when ingested in therapeutically effective amounts.
The invention further provides an effective synthesis for polymers having hydrophilic and hydrophobic units by conducting the reaction in the presence of an alcoholic solvent not normally considered a good polymerization solvent due to its chain transfer properties.
Other features and advantages will be apparent from the following description of the preferred embodiments thereof and from the claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Compositions
Preferred polymer have the formulae set forth in the Summary of the Invention, above. The polymers are highly crosslinked. The high level of crosslinking makes the polymers completely insoluble and thus limits the activity of the alkylated reaction product to the gastrointestinal tract only. Thus, the compositions are non-systemic in their activity and will lead to reduced side-effects in the patient.
The polymers are preferably crosslinked by adding a crosslinking co-monomer to the reaction mixture during polymerization. Examples of suitable crosslinking co-monomers include diacrylates and dimethacrylates (e.g., ethylene glycol diacrylate, propylene glycol diacrylate, butylene glycol diacrylate, ethylene glycol dimethacrylate, propylene glycol dimethacrylate, butylene glycol dimethacrylate, polyethyleneglycol dimethacrylate, polyethyleneglycol diacrylate), methylene bisacrylamide, methylene bismethacrylamide, ethylene bisacrylamide, ethylenebismethacrylamide, ethylidene bisacrylamide, divinyl benzene, bisphenol A dimethacrylate, and bisphenol A diacrylate. These crosslinking co-monomers are either commercially available or are prepared as described in Mandeville et al., "Process for Adjusting Ion Concentration in a Patient and Compositions Therefor, " U.S. Ser. No. 08/065,113, filed May 20, 1993, assigned to the same assignee as the present application and hereby incorporated by reference. The amount of crosslinking agent is typically between 1.0 and 25 weight %, based upon combined weight of crosslinking agent and monomer, with 2.5-20% being preferred.
Preferably, the polymer includes one or more co-monomers that increase the overall hydrophobicity of the polymer. Because bile salts are hydrophobic, the hydrophobic co-monomer aids in maximizing the selectivity of the interaction of the polymer with the bile salts.
Examples of suitable hydrophobic co-monomers include, e.g., acrylamide, methacrylamide, and N-alkyl (e.g., methyl, ethyl, isopropyl, butyl, hexyl, dodecyl, cyclohexyl, dicyclohexyl) and N-aryl (e.g., phenyl, diphenyl) derivatives thereof; alkyl and aryl acrylates and methacrylates (e.g., ethyl, propyl, butyl, dodecyl), and fluorinated derivatives thereof (e.g., hexafluoroisopropyl acrylate, hexafluorobutyl methacrylate, heptadecafluorodecyl acrylate); styrene and derivatives thereof (e.g., dimethylaminomethyl styrene, 4-aminostyrene, and fluorinated derivatives, e.g., p-fluorostyrene, pentafluorostyrene); ethylvinylbenzene; vinyl naphthalene; vinyl pyridine; vinyl imidazole; 4-vinylbiphenyl; 4,4-vinylanisole; and combinations thereof. The amount of hydrophobic co-monomer used in the preparation of these polymers is from 1 to 75% by weight, preferably from 3 to 65%.
The level of hydrophobicity needed may also be achieved simply by appropriate choice of crosslinking co-monomer. For example, divinylbenzene is a suitable crosslinking co-monomer and is hydrophobic as well. In addition, the main "impurity" in divinylbenzene is ethylvinylbenzene, a hydrophobic, polymerizable monomer which will also contribute to the overall hydrophobicity of the polymer. Other hydrophobic crosslinking co-monomers include bisphenol A diacrylate and bisphenol A dimethacrylate.
The crosslinked polymers may be reacted with one or more alkylating agents. Examples of preferred alkylating agents are set forth in the Summary of the Invention, above.
EXAMPLES
A. Polymer Preparation
1. Preparation of Poly (methacrylamidopropyltrimethylammonium chloride) (PolyMAPTAC)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyltrimethylammonium chloride (MAPTAC) (40 mL of a 50% aqueous solution, 21 g), ethylene glycol dimethacrylate crosslinking co-monomer (5.00 g, 4.76 mL), ethyl acetate (200 mL), and 2-propanol (200 mL). The resulting solution was clear. Next, the polymerization initiator AIBN (0.1 g) was added and the reaction mixture was heated to 65° C. When the temperature reached 65° C. the solution was degassed with nitrogen for 5 minutes, at which point it turned cloudy, indicating that polymerization was proceeding. The reaction was maintained at 65° C. for another 3 hours and then allowed to cool to room temperature.
The resulting polymer (which was hard and sticky) was combined with 500 mL of water to soften it, and then transferred to a blender where it was blended with 1500 mL of 2-propanol and centrifuged. The mixture was then decanted and transferred to another blender with the aid of 100 mL of water. 800 mL of 2-propanol was then added and the mixture was blended, allowed to settle, and decanted. The mixture was then combined with 1000 mL of 2-propanol, blended, filtered, and vacuum-dried to afford 12.6 g of polymer.
PolyMAPTAC crosslinked with 0.5% methylenebismethacrylamide crosslinking co-monomer; polyMAPTAC crosslinked with 10% methylenebismethacrylamide crosslinking co-monomer; and polyMAPTAC crosslinked with 10% divinylbenzene crosslinking co-monomer were prepared in analogous fashion.
2. Preparation of Poly (vinylamine)
The first step involved the preparation of ethylidenebisacetamide. Acetamide (118 g), acetaldehyde (44.06 g), copper acetate (0.2 g), and water (300 mL) were placed in a 1 L three neck flask fitted with condenser, thermometer, and mechanical stirrer. Concentrated HCl(34 mL) was added and the mixture was heated to 45°-50° C. with stirring for 24 h. The water was then removed in vacuo to leave a thick sludge which formed crystals on cooling to 5° C. Acetone (200 mL) was added and stirred for a few minutes, after which the solid was filtered off and discarded. The acetone was cooled to 0° C and solid was filtered off. This solid was rinsed in 500 mL acetone and air dried 18 h to yield 31.5 g of ethylidenebisacetamide.
The next step involved the preparation of vinylacetamide from ethylidenebisacetamide. Ethylidenebisacetamide (31.05 g), calcium carbonate (2 g) and celite 541 (2 g) were placed in a 500 mL three neck flask fitted with a thermometer, a mechanical stirrer, and a distilling head atop a Vigreux column. The mixture was vacuum distilled at 35 mm Hg by heating the pot to 180°-225° C. Only a single fraction was collected (10.8 g) which contained a large portion of acetamide in addition to the product (determined by NMR). This solid product was dissolved in isopropanol (30 mL) to form the crude vinylacetamide solution used for polymerization.
Crude vinylacetamide solution (15 mL), divinylbenzene (1 g, technical grade, 55% pure, mixed isomers), and AIBN (0.3 g) were mixed and heated to reflux under a nitrogen atmosphere for 90 min, forming a solid precipitate. The solution was cooled, isopropanol (50 mL) was added, and the solid was collected by centrifugation. The solid was rinsed twice in isopropanol, once in water, and dried in a vacuum oven to yield 0.8 g of poly(vinylacetamide), which was used to prepare poly(vinylamine as follows).
Poly(vinylacetamide) (0.79 g) was placed in a 100 mL one neck flask containing water (25 mL) and conc. HCl (25 mL). The mixture was refluxed for 5 days, after which the solid was filtered off, rinsed once in water, twice in isopropanol, and dried in a vacuum oven to yield 0.77 g of product. Infrared spectroscopy indicated that a significant amount of the amide (1656 cm -1 ) remained and that not much amine (1606 cm -1 ) was formed. The product of this reaction (˜0.84 g) was suspended in NaOH (46 g) and water (46 g) and heated to boiling (˜140°0 C.). Due to foaming the temperature was reduced and maintained at ˜100° C for 2 h. Water (100 mL) was added and the solid collected by filtration. After rinsing once in water the solid was suspended in water (500 mL) and adjusted to pH 5 with acetic acid. The solid was again filtered off, rinsed with water, then isopropanol, and dried in a vacuum oven to yield 0.51 g of product. Infrared spectroscopy indicated that significant amine had been formed.
3. Preparation of Poly(3-dimethylaminopropylacrylamide (DMAPA)
Dimethylaminopropylacrylamide (10 g) and methylenebisacrylamide crosslinking co-monomer (1.1 g) were dissolved in 50 mL of water in a 100 mL three neck flask. The solution was stirred under nitrogen for 10 minutes. Potassium persulfate (0.3 g) and sodium metabisulfite (0.3 g) were each dissolved in 2-3 mL of water and then mixed. After a few seconds this solution was added to the monomer solution, still under nitrogen. A gel formed immediately and was allowed to sit overnight. The gel was removed and blended with 500 mL of isopropanol. The solid was filtered off and rinsed three times with acetone. The solid white powder was filtered off and dried in a vacuum oven to yield 6.1 g.
4. Preparation of Poly(dimethylaminopropylacrylamide hydrochloride) (DMAPA. HCl)
Dimethylaminopropylacrylamide (20.10 g) was dissolved in water (100 mL) and neutralized with concentrated HCl to pH 6.95. Methylenebisacrylamide crosslinking co-monomer (2.2 g) and water (100 mL) were added and warmed (34°0 C.) to dissolve. Potassium persulfate (0.2 g) and potassium metabisulfite (0.2 g) were added with stirring. After gellation, the solution was allowed to sit for 6 h, blended with isopropanol (600 mL) three times, and dried in a vacuum oven to yield 14.47 g of the title polymer.
PolyDMAPA.HCl crosslinked with 10% methylenebismethacrylamide crosslinking co-monomer was prepared in analogous fashion.
5. Preparation of Poly(dimethylaminopropylmethacrylamide hydrochloride) (DMAPMA. HCl)
Dimethylaminopropylmethacrylamide (20.0 g) was dissolved in water (100 mL) and neutralized with concentrated HCl to pH 6.94. Methylenebisacrylamide crosslinking co-monomer (2.2 g) was added and the solution was warmed (39° C. ) to dissolve. Potassium persulfate (0.3 g) and potassium metabisulfite (0.3 g) were added with stirring under a nitrogen atmosphere. After gellation, the solution was allowed to sit overnight, blended with isopropanol (500 mL) twice, and dried in a vacuum oven to yield 27.65 g of product. Some of the solid (3.2 g; sieved to -80/+200 mesh size) was stirred in water (100 mL) for 50 min, additional water (100 mL) was added and the solution stirred for 36 min. The solid was collected by centrifugation, resuspended in water (400 mL), stirred 150 min, and again collected by centrifugation. The solid was finally resuspended in water (500 mL), stirred 90 min, and collected by filtration. The solid was dried in a vacuum oven to yield 0.28 g of the title polymer.
6. Preparation of Poly(methacrylamidopropyltrimethylammonium chloride) co-poly(n-butylmethacrylamide) (MAPTAC co-BuMA)
The co-monomer n-butylmethacrylamide (BuMA) was prepared as follows.
Methacryloyl chloride (48.4 mL, 52.3 g, 0.500 mol) was dissolved in tetrahydrofuran (300 mL) in a 1 L flask and placed in an ice bath. A solution containing butylamine (36.6 g) and triethylamine (55.6 g) was added dropwise, maintaining the temperature at 5°-15° C. After addition the solution was stirred for 5 min and the solid triethylamine hydrochloride was filtered off and discarded. The solvent was removed in vacuo from the mother liquor and the resulting yellow oil was used without further purification. The yield was 71.58 g of BuMA co-monomer.
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyltrimethylammonium chloride (MAPTAC) (108 mL of a 50% aqueous solution, 56.8 g), ethylene glycol dimethacrylate crosslinking co-monomer (19.62 g), BuMA co-monomer (12.12 g), and 2-propanol (850 mL). The resulting solution was clear. Next, the reaction mixture was heated to 40° C. while being degassed with nitrogen. When the solution had reached 40° C., the catalyst, consisting of a solution of potassium persulfate (0.75 g) and potassium metabisulfate (0.75 g) in 25 mL of water was added. The solution immediately began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 40° C. for 24 hours and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and vacuum dried to afford 64.54 g of the title polymer.
Polymer for testing was washed two times with 800 mL of water each time, followed by two washes with 500 mL of methanol each time to give 34.5 g of purified polymer.
A crosslinked MAPTAC co-BuMA copolymer was also prepared using propylene glycol dimethacrylate, rather than ethylene glycol dimethacrylate, as the crosslinking co-monomer, as follows.
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyltrimethylammonium chloride (MAPTAC) (60 mL of a 50% aqueous solution, 31.5 g), propylene glycol dimethacrylate crosslinking co-monomer (9.81 g), BuMA co-monomer (6.06 g), and 2-propanol (300 mL). The resulting solution was clear. Next, the reaction mixture was heated to 70° C. while being degassed with nitrogen. When the solution had reached 70° C, the catalyst, AIBN (0.50 g), was added. The solution immediately began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 70° C. for 6 hours and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and vacuum dried to afford 23.3 g of polymer.
MAPTAC coBuMA (5%) crosslinked with 24% ethyleneglycoldimethacrylate crosslinking co-monomer, MAPTAC coBuMA (2)%) crosslinked with 0.5% methylenebismethacrylamide crosslinking co-monomer, and MAPTAC coBuMA (14%) crosslinked with 22% propyleneglycoldimethacrylate crosslinking co-monomer were prepared in analogous fashion by adjusting the ratios of starting monomers.
7. Preparation of Poly(methacrylamidopropyltrimethylammonium chloride) co-poly(styrene) (MAPTAC co-Sty)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyltrimethyl-ammonium chloride (MAPTAC) (60 mL of a 50% aqueous solution, 31.5 g), divinyl benzene crosslinking co-monomer (2.00 g), styrene co-monomer (1.75 g), and 2-propanol (300 mL). The resulting solution was clear. Next, the reaction mixture was heated to 60° C. while being degassed with nitrogen. When the solution had reached 60° C. , the catalyst, AIBN (0.50 g), was added. The solution immediately began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 60° C. for 24 hours and then allowed to cool to room temperature. After about 7 hours the mixture had become very thick and 100 mL additional isopropanol was added to allow for better stirring.
The resulting polymer was filtered and washed on the funnel with isopropanol and vacuum dried to afford 30.9 g of the title polymer.
Polymer for testing was washed two times with 1000 mL of water each time followed by two washes with 800 mL of methanol each time to give 28.0 g of purified polymer.
MAPTAC co-Sty (13%) crosslinked with 7.5% butyleneglycoldimethacrylate crosslinking co-monomer, MAPTAC co-Sty (13%) crosslinked with 20% butyleneglycoldimethacrylate crosslinking co-monomer, MAPTAC co-Sty (19%) crosslinked with 6% divinylbenzene co-monomer, MAPTAC co-Sty (23%) crosslinked with 7% divinylbenzene co-monomer, MAPTAC co-Sty (30%) crosslinked with 6% divinylbenzene co-monomer, and MAPTAC co-Sty (38%) crosslinked with 6% divinylbenzene co-monomer were prepared in analogous fashion by varying the ratios of starting monomers.
8. Preparation of Poly(methacrylamidopropyltrimethylammonium chloride) co-poly(vinyl naphthalene) (MAPTAC co-VN)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyltrimethylammonium chloride (MAPTAC) (40 mL of a 50% aqueous solution, 21.0 g), divinyl benzene crosslinking co-monomer (2.25 g), 2-vinylnaphthalene co-monomer (10.5 g), and 2-propanol (320 mL). The resulting solution was clear. Next, the reaction mixture was heated to 65° C. while being degassed with nitrogen. When the solution had reached 65° C. , the catalyst, AIBN (0.50 g), was added. The solution immediately began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 65° C. for 20 hours and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and then immediately slurried in 400 mL of distilled water. The mixture was stirred for 1/2 hour and then filtered. The water wash was repeated one more time. The filter cake was then slurried in 400 mL of methanol and stirred for 1/2 hour. The mixture was filtered and the methanol slurry was repeated one more time. Vacuum drying afforded 22.11 g, 65.5% of the title polymer.
MAPTAC co-VN (39%) crosslinked with 5% divinyl benzene crosslinking co-monomer was prepared in analogous fashion by varying the ratio of starting monomers.
9. Preparation of Poly(methacrylamidopropyltrimethylammonium chloride) co-poly(1-vinyl imidazole) (MAPTAC co-VI)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyltrimethylammonium chloride (MAPTAC) (40 mL of a 50% aqueous solution, 21.0 g), divinyl benzene crosslinking co-monomer (2.25 g), 1-vinylimidazole co-monomer (12.54 g), and 2-propanol (300 mL). The resulting solution was clear. Next, the reaction mixture was heated to 65° C. while being degassed with nitrogen. When the solution had reached 65° C., the catalyst, AIBN (0.50 g), was added. The solution immediately began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 65°0 C. for 20 hours and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol, and then immediately slurried in 500 mL of distilled water. The mixture was stirred for 1/2 hour and then filtered. The water wash was repeated one more time. The filter cake was then slurried in 400 mL of methanol and stirred for 1/2 hour. The mixture was filtered and the methanol slurry was repeated one more time. Vacuum drying afforded 7.34 g, 20.5% of the title polymer.
10. Preparation of Poly(trimethylammoniumethylacrylatechloride) co-poly(styrene) (TMAEAC co-Sty)
To a 1000 mL, three-necked, round-bottomed flask was added the following: trimethylammoniumethylacrylatechloride (TMAEAC) (99.4 mL of a 50% aqueous solution, 53.0 g), divinyl benzene crosslinking co-monomer (7.00 g), styrene co-monomer (40.0 g), and 2-propanol (800 mL). The resulting solution was clear. Next, the reaction mixture was heated to 65° C. while being degassed with nitrogen. When the solution had reached 65° C., the catalyst, AIBN (1.50 g), was added. The solution immediately began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 65° C. for 6 hours, then cooled to 60° C. and stirred for an additional 18 hours. It was then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol, and then immediately slurried in 1000 mL of distilled water. The mixture was stirred for 1/2 hour and then 800 mL of methanol was added and the mixture was stirred for an additional 1/2 hour. The mixture was allowed to settle and the supernatant liquid was decanted, leaving a residue of about 750 mL. The residue was then slurried with an additional 750 mL of methanol and stirred for 1/2 hour. The methanol slurry and decantation process was repeated two more times with 800 mL of methanol each time. Next, 800 mL of isopropanol was added and the mixture was stirred for 1/2 hour and then filtered. Finally, 600 mL of isopropanol was added and the mixture was stirred for 1/2 hour. Filtration and vacuum drying afforded 49.2 g, 49.2% of the title polymer.
TMAEAC co-Sty (31%) crosslinked with 8% divinylbenzene crosslinking co-monomer and TMAEAC co-Sty (46%) crosslinked with 6% divinylbenzene crosslinking co-monomer were prepared in analogous fashion by varying the ratio of starting monomers.
11. Preparation of Poly(trimethylammoniumethylmethacrylatechloride co-poly(styrene) (TMAEMC co-Sty)
To a 1000 mL, three-necked, round-bottomed flask was added the following: trimethylammoniumethylmethacrylatechloride (TMAEMAC) (38.8 mL of a 50% aqueous solution, 21.7 g), divinyl benzene crosslinking co-monomer (3.72 g), styrene co-monomer (15.66 g), and 2-propanol (2500 mL). The resulting solution was clear. Next, the reaction mixture was heated to 65° C. while being degassed with nitrogen. When the solution had reached 65° C., the catalyst, AIBN (0.50 g), was added. The solution immediately began to turn cloudy, indicating that polymerization was proceeding. After two hours, the mixture became very thick and an additional 100 mL of isopropanol was added. After five hours the mixture was again very thick so an additional 100 mL of isopropanol was added. The reaction was maintained at 65° C. for 6 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol, and then immediately slurried in 1000 mL of distilled water. The mixture was stirred for 1/2 hour and then transferred to a blender and blended for five minutes. The polymer slurry was filtered and 1000 mL of distilled water was added and the mixture was stirred for 1/2 hour. The mixture was filtered and the filter cake was slurried two times in 500 mL of methanol each time. Filtration and vacuum drying afforded 30.2 g, 75.9% of the title polymer.
TMAEMC co-Sty (58%) crosslinked with 4% divinylbenzene crosslinking co-monomer, TMAEMC co-Sty (33%) crosslinked with 4% divinylbenzene crosslinking co-monomer, and TMAEMC co-Sty (24%) crosslinked with 4% divinylbenzene crosslinking co-monomer were prepared in analogous fashion by varying the ratio of starting monomers.
12. Preparation of Poly(methacrylamidopropyl-3-(trimethylammonium) (chloride), co-(poly 2, 3, 4, 5, 6-pentafluorostyrene) (MAPTAC co-StyF 5 )
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyl-3-(trimethylammonium) chloride (MAPTAC) (24.5 mL of a 50% aqueous solution, 13.00 g), divinylbenzene crosslinking co-monomer (1.00 g), pentafluorostyrene (6.00 g), 2-propanol (150 mL), and AIBN (0.50 g). The resulting solution was clear. Next, the reaction mixture was heated to 65° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. After five hours the mixture was very thick so an additional 100 mL of isopropanol was added. The reaction was maintained at 65° C. for 24 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 500 mL of distilled water. The mixture was stirred for 1/2 hour. The polymer slurry was filtered and 500 mL of distilled water was added and the mixture was stirred for 1/2 hour. The mixture was filtered and the filter cake was slurried two times in 300 mL of methanol each time. Filtration and air drying afforded 7.74 g of the title co-polymer.
MAPTAC co-StyF 5 (20%) crosslinked with 5% divinylbenzene crosslinking co-monomer, MAPTAC co-StyF 5 (40%) crosslinked with 5% divinylbenzene crosslinking co-monomer, and MAPTAC co-StyF 5 (45%) crosslinked with 5% divinylbenzene crosslinking co-monomer were prepared in analogous fashion by varying the ratio of starting monomers.
13. Preparation of poly(methacrylamidopropyl-3-(trimethylammonium) chloride), co-poly 2-(trimethylammonium) ethyl methacrylate chloride, co-styrene (MAPTAC co-TMAEMC co-Sty)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyl-3-(trimethylammonium) chloride (MAPTAC) (10.40 g of a 50% aqueous solution, 5.20 g), 2-(trimethylammonium) ethyl methacrylate chloride (TMAEMC) (4.86 g of a 70% aqueous solution, 3.40 g) divinylbenzene crosslinking co-monomer (1.00 g), styrene (10.40 g), 2-propanol (150 mL), and AIBN (0.50 g). The resulting solution was clear. Next, the reaction mixture was heated to 70° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 70° C. for 24 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 500 mL of methanol. The mixture was stirred for 1/2 hour. The polymer slurry was filtered and 400 mL of distilled water was added and the mixture was stirred for 1/2 hour. The mixture was filtered and the water slurry was repeated. The mixture was filtered and the filter cake was slurried two times in 400 mL of methanol each time. Filtration and air drying afforded 5.39 g of the title co-polymer.
MAPTAC co-TMAEMC (34%) co-Sty (36%) crosslinked with 5% divinylbenzene crosslinking co-monomer, MAPTAC co-TMAEMC (31%) co-Sty (41%) crosslinked with 5% divinylbenzene crosslinking co-monomer, MAPTAC co-TMAEMC (28%) co-Sty (46%) crosslinked with 5% divinylbenzene crosslinking co-monomer, MAPTAC co-TMAEMC (23%) co-Sty (48%) crosslinked with 5% divinylbenzene crosslinking co-monomer, MAPTAC co-TMAEMC (26%) co-Sty (52%) crosslinked with 4% divinylbenzene crosslinking co-monomer, MAPTAC co-TMAEMC (17%) co-Sty (53%) crosslinked with 4% divinylbenzene crosslinking co-monomer, MAPTAC co-TMAEMC (15%) co-Sty (55%) crosslinked with 4% divinylbenzene crosslinking co-monomer, and MAPTAC co-TMAEMC (13%) co-Sty (61.5%) crosslinked with 4% divinylbenzene crosslinking co-monomer were prepared in analogous fashion by varying the ratio of starting monomers.
14. Preparation of Poly(trimethylammoniumethylmethacrylatechloride co-poly(isopropylacrylamide)) (TMAEMAC co-IPA)
The co-monomer isopropylacrylamide (IPA) was first prepared as follows.
Acryloyl chloride (63 mL, 70.2 g, 0,775 mol) was dissolved in tetrahydrofuran (200 mL) in a 1 L flask and placed in an ice bath. A solution containing isopropylamine (127.7 mL, 88.67 g, 1.50 mol) was added dropwise, maintaining the temperature at 5°-15° C. After addition the solution was stirred for 10 min and the solid isopropylamine hydrochloride was filtered off and discarded. The solvent was removed in vacuo from the mother liquor and the resulting almost colorless oil, which solidified on standing, was used without further purification to prepare the title co-polymer as follows.
To a 1000 mL, three-necked, round-bottomed flask was added the following: trimethylammoniumethylacrylate chloride (76.5 mL of a 50% aqueous solution, 41.18 g, 0,213 mol), methylene bis acrylamide crosslinking co-monomer (2.40 g), IPA co-monomer (4.52 g, 0.070 mol), and water (200 mL). The resulting solution was clear. The reaction mixture was stirred while being degassed with nitrogen. When the solution had been degassed, the catalyst, consisting of potassium persulfate (0.3 g) and potassium metabisulfate (0.3 g) was added. The polymerization initiated after 2 minutes and gelled after 3 minutes.
The next morning the gel was transferred to a blender and 1000 mL of water was added. After blending for a few seconds, the polymer had swelled to take up all of the water. The swollen polymer was blended in several portions with isopropanol several times to dehydrate it. The resulting polymer was filtered and washed on the funnel with isopropanol and vacuum dried to afford 36.8 g of the title co-polymer.
15. Preparation of Poly(methacrylamidopropyl-3-(trimethylammonium chloride)) co-poly(vinyl pyridine) (MAPTAC co-VP)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyl-3-(trimethylammonium) chloride (MAPTAC) (40 mL of a 50% aqueous solution, 21.0 g), divinyl benzene crosslinking co-monomer (2.25 g), vinyl pyridine (14.0 g, 0.133 mol), conc. hydrochloric acid (11 mL, 0,133 mol), 2-propanol (300 mL), and AIBN (0.67 g). The resulting solution was clear. Next, the reaction mixture was heated to 60° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 60° C. for 20 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 1000 mL of distilled water. The mixture was stirred for 1 hour. The polymer slurry was filtered, washed on the funnel with methanol, and then slurried in 600 mL of methanol for one hour. Filtration and air drying afforded 20.4 g of copolymer.
16. Preparation of Poly(trimethylammoniumethylmethacrylate chloride) co-poly(p-fluorostyrene) (TMAEMC co-F 1 Sty)
To a 500 mL flask was added the following: trimethylammoniumethylmethacrylate chloride (TMAEMC) (11.0 g of a 70% aqueous solution, 7.70 g), divinylbenzene crosslinking co-monomer (0.50 g), p-fluorostyrene co-monomer (4.00 g), 2-propanol (125 mL) and AIBN (0.25 g). The resulting solution was clear. Next, the reaction mixture was heated to 65° C. while being degassed with nitrogen. The solution immediately began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 65° C. for 6 hours, and then allowed to cool to room temperature.
The solvent was removed by decantation and the polymer was immediately slurried in 250 mL of distilled water. The mixture was stirred for 1/2 hour and then decanted. The water slurry was repeated three more times. Finally, the polymer was slurried in 400 mL of methanol. Filtration and vacuum drying afforded 5.42 g, 44.4% of the title copolymer.
TMAEMC co-F 1 Sty (24%) crosslinked with 4% divinylbenzene crosslinking co-monomer was prepared in analogous fashion by varying the ratio of the starting monomers.
17. Preparation of Poly(methacrylamidopropyl-3-(trimethyl ammonium chloride)) co -poly (hexafluorobutyl methacrylate) (MAPTAC coF 6 BMA)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyl-3-(trimethylammonium) chloride (MAPTAC) (28.5 mL of a 50% aqueous solution, 15.0 g), divinylbenzene crosslinking co-monomer (1.00 g), hexafluorobutyl methacrylate (4.00 g), 2propanol (150 mL), and AIBN (0.50 g). The resulting solution was clear. Next, the reaction mixture was heated to 60° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 60° C. for 24 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 500 mL of distilled water. The mixture was stirred for 1 hour. The polymer slurry was filtered and the water slurry was repeated one more time. The polymer was then slurried in 500 mL of methanol for one hour and filtered. The methanol slurry was repeated one more time. Finally the polymer was slurried in 400 mL of isopropanol and stirred overnight. Filtration and air drying afforded 7.52 g of the title copolymer.
18. Preparation of Poly(trimethylammoniumethylacrylate chloride) co-poly (hexafluoroisopropyl acrylate) (TMAEAC co-F 6 IA)
To a 1000 mL, three-necked, round-bottomed flask was added the following: trimethylammoniumethylacrylate chloride (30.0 mL of a 50% aqueous solution, 15.0 g), divinylbenzene crosslinking co-monomer (1.00 g), F 6 IPA co-monomer (4.00 g), AIBN (0.50 g), and isopropanol (150 mL). The resulting solution was clear. The reaction mixture was stirred while being degassed with nitrogen and heated to 60° C. After 18 hours the reaction mixture was allowed to cool to room temperature and the solvent was removed by decanting. The residual polymer was slurried in 400 mL of water, stirred for one hour and filtered. The water slurry was repeated one more time. Next the polymer was slurried two times in methanol. Finally, the polymer was slurried in 200 mL of isopropanol, stirred for two hours and filtered. Air drying afforded 5.59 g of the title polymer.
19. Preparation of Poly(methacrylamidopropyl-3-(trimethyl ammonium chloride) ) co -poly (heptadecafluorodecyl methacrylate) (MAPTAC coF 17 DecMA)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyl-3-(trimethylammonium) chloride (MAPTAC) (28.5 mL of a 50% aqueous solution, 15.0 g), divinylbenzene crosslinking co-monomer (1.00 g), heptadecafluorodecyl methacrylate (4.00 g), 2-propanol (150 mL), and AIBN (0.40 g). The resulting solution was clear. Next, the reaction mixture was heated to 65° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. After four hours, the reaction mixture had gotten very thick and 100 mL more isopropanol was added. The reaction was maintained at 65° C. for 18 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 600 mL of distilled water. The mixture was stirred for 1 hour. The polymer slurry was filtered and the water slurry was repeated one more time. The polymer was then slurried in 500 mL of methanol for one hour and filtered. Air drying afforded 17.73 g of co-polymer.
20. Preparation of poly(methacrylamidopropyl-3-(trimethylammonium chloride)), co-poly (2-(trimethylammonium) ethyl acrylate chloride), co -poly styrene (MAPTAC co-TMAEAC co-Sty)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyl-3-(trimethylammonium) chloride (MAPTAC) (10.00 g of a 50% aqueous solution, 5.00 g), 2-(trimethylammonium) ethyl methacrylate chloride (TMAEAC) (6.00 g of a 50% aqueous solution, 3.00 g) divinylbenzene crosslinking co-monomer (1.00 g), styrene (11.00 g), 2-propanol (150 mL), and AIBN (0.25 g). The resulting solution was clear. Next, the reaction mixture was heated to 70° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 70° C. for 24 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 500 mL of methanol. The mixture was stirred for 1/2 hour. The polymer slurry was allowed to settle and decanted. 200 mL of distilled water was added and the mixture was stirred for 1/2 hour. The mixture was decanted and the water slurry was repeated with 400 mL. The mixture was decanted and the polymer was slurried two times in 200 mL of methanol each time. Filtration and air drying afforded 2.76 g of the title co-polymer.
MAPTAC co-TMAEAC (10%) co-Sty (60%) crosslinked with 5% divinylbenzene crosslinking co-monomer was prepared in analogous fashion by varying the ratio of starting monomers.
21. Preparation of poly (2-(trimethylammonium) ethyl acrylate chloride) co-poly (2,3,4,5,6-pentafluorostyrene) (TMAEAC co-StyF 5 )
To a 1000 mL, three-necked, round-bottomed flask was added the following: 2-(trimethylammonium) ethyl acrylate chloride (TMAEAC) (24.0 mL of a 50% aqueous solution, 13.00 g), divinylbenzene crosslinking co-monomer (1.00 g), pentafluorostyrene (6.00 g), 2-propanol (150 mL), and AIBN (0.50 g). The resulting solution was clear. Next, the reaction mixture was heated to 65° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. After two hours the mixture was very thick so an additional 100 mL of isopropanol was added. The reaction was maintained at 65° C. for 22 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 400 mL of distilled water. The mixture was stirred for 1/2 hour. The polymer slurry was filtered and 600 mL of distilled water was added and the mixture was stirred for 1/2 hour. The mixture was filtered and the filter cake was slurried in 400 mL of methanol. Filtration and air drying afforded 7.26 g of the title co-polymer.
TMAEAC co-StyF 5 (20%) crosslinked with 5% divinylbenzene crosslinking co-monomer was prepared in analogous fashion by varying the ratio of starting monomers.
22. Preparation of poly (2-(trimethylammonium) ethyl
methacrylate chloride), co-poly (2,3,4,5,6-pentafluorostyrene) (TMAEMC co-StyF 5 )
To a 1000 mL, three-necked, round-bottomed flask was added the following: 2-(trimethylammonium) ethyl methacrylate chloride (TMAEMC) (19.52 of a 70% aqueous solution, 13.66 g), divinylbenzene crosslinking co-monomer (1.00 g), pentafluorostyrene (9.18 g), 2-propanol (150 mL), and AIBN (0.40 g). The resulting solution was clear. Next, the reaction mixture was heated to 70° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. After 1.5 hours the mixture was very thick so an additional 50 mL of isopropanol was added. The reaction was maintained at 70° C. for 5 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 500 mL of distilled water. The mixture was stirred for 1/4 hour. The polymer slurry was filtered and 500 mL of distilled water was added and the mixture was stirred for 1/4 hour. The water slurry was repeated one more time. The mixture was filtered and the filter cake was slurried three times in 300 mL of methanol each time. Filtration and air drying afforded 1.26 g of the title co-polymer.
TMAEMC co-StyF 5 (24%) crosslinked with 4% divinylbenzene crosslinking co-monomer and TMAEMC co-StyF 5 (39%) crosslinked with 4% divinylbenzene crosslinking co-monomer were prepared in analogous fashion by varying the ratio of starting monomers.
23. Preparation of Poly(ethyleneimine)
Polyethyleneimine (120 g of a 50% aqueous solution; Scientific Polymer Products) was dissolved in water (250 mL). Epichlorohydrin (22.1 mL) was added dropwise. The solution was heated to 60° C. for 4 h, after which it had gelled. The gel was removed, blended with water (1.5 L) and the solid was filtered off, rinsed three times with water (3 L) and twice with isopropanol (3 L), and the resulting gel was dried in a vacuum oven to yield 81.2 g of the title polymer.
24. Preparation of Poly(methacrylamidopropyl-3-(trimethylammonium chloride) ), co-poly(2-(trimethylammonium) ethylmethacrylate chloride) ) co-poly (2,3,4,5,6-pentafluorostyrene) (MAPTAC co -TMAEMC co-StyF 5 )
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyl-3-(trimethylammonium) chloride (MAPTAC) (10.00 of a 50% aqueous solution, 5.00 g), 2-(trimethylammonium) ethyl methacrylate chloride (TMAEMC) (5.71 g of a 70% aqueous solution, 4.00 g), divinylbenzene crosslinking co-monomer (1.00 g), pentafluorostyrene (10.00 g), 2-propanol (150 mL), and AIBN (0.50 g). The resulting solution was clear. Next, the reaction mixture was heated to 70° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 70° C. for 24 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 500 mL of methanol. The mixture was stirred for 1/4 hour. The polymer slurry was filtered and then slurried 3 times in 300 mL of water each time. The last time the polymer slurry was blended for 5 minutes. The mixture was filtered and the filter cake was slurried two times in 300 mL of methanol each time. Filtration and vacuum drying afforded 9.74 g of co-polymer.
25. Preparation of poly (2-(trimethylammonium) ethyl acrylate chloride), co-poly (2-(trimethylammonium) ethylmethacrylate chloride) co-styrene (TMAEAC, co-TMAEMC, co-Sty)
To a 1000 mL, three-necked, round-bottomed flask was added the following: 2-(trimethylammonium) ethyl acrylate chloride (TMAEAC) (6.00 g of a 50% aqueous solution, 3.00 g), 2-(trimethylammonium) ethyl methacrylate chloride (TMAEMC) (4.29 g of a 70% aqueous solution, 3.00 g), divinylbenzene crosslinking co-monomer (1.00 g), styrene (13.00 g), 2-propanol (150 mL), and AIBN (0.50 g). The resulting solution was clear. Next, the reaction mixture was heated to 70° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 70° C. for 24 hours, and then allowed to cool to room temperature.
The resulting polymer was decanted and immediately slurried in 500 mL of methanol. The mixture was stirred for 1/2 hour. The polymer slurry was filtered and 500 mL of distilled water was added. The mixture was then stirred for 1/2 hour and blended for 10 minutes. The mixture was allowed to settle and the water was decanted. The water slurry was repeated two more times and the decantation residue was slurried two times in 400 mL of methanol each time, settling and decanting each time. Vacuum drying afforded 8.03 g of the title co-polymer.
26. Preparation of Poly(methacrylamidopropyl-3-(trimethylammonium) chloride), co-poly(2-(trimethylammonium) ethylacrylate chloride) co -poly (2,3,4,5,6-pentafluorostyrene) (MAPTAC co -TMAEAC co-StyF 5 )
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyl-3-(trimethylammonium) chloride (MAPTAC) (8.00 g of a 50% aqueous solution, 4.00 g), 2-(trimethylammonium) ethyl acrylate chloride (TMAEMA) (6.00 g of a 50% aqueous solution, 3.00 g), divinylbenzene crosslinking co-monomer (1.00 g), pentafluorostyrene (12.00 g), 2-propanol (150 mL), and AIBN (0.50 g). The resulting solution was clear. Next, the reaction mixture was heated to 70° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 70° C. for 24 hours, and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the funnel with isopropanol and immediately slurried in 400 mL of methanol. The mixture was stirred for 1/2 hour. The polymer slurry was filtered and then slurried 2 times in 250 mL of water each time. The last time the polymer slurry was blended for 5 minutes. The mixture was filtered and the filter cake was slurried two times in 250 mL of methanol each time. Filtration and vacuum drying afforded 7.80 g of co-polymer.
27. Preparation of Poly ((trimethylammonium) ethyl acrylate chloride), co-poly(2-(trimethylammonium) ethylmethacrylate chloride) co-poly (2,3,4,5,6-pentafluorostyrene) (TMAEAC, co-TMAEMC, co-StyF 5 )
To a 1000 mL, three-necked, round-bottomed flask was added the following: 2-(trimethylammonium) ethyl acrylate chloride (TMAEAC) (6.00 g of a 50% aqueous solution, 3.00 g), 2-(trimethylammonium) ethyl methacrylate chloride (TMAEMC) (4.29 g of a 70% aqueous solution, 3.00 g), divinylbenzene crosslinking co-monomer (1.00 g), pentafluorostyrene (13.00 g), 2-propanol (150 mL), and AIBN (0.50 g). The resulting solution was clear. Next, the reaction mixture was heated to 70° C. while being degassed with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 70° C. for 24 hours, and then allowed to cool to room temperature.
The resulting polymer was decanted and immediately slurried in 400 mL of methanol. The mixture was stirred for 1/2 hour. The polymer slurry was filtered and then slurried two times in 200 mL of water each time. The second time the polymer slurry was blended for 5 minutes. The mixture was filtered and the filter cake was slurried two times in 200 mL of methanol each time. Vacuum drying afforded 6.87 g of co-polymer.
28. Preparation of Poly (methacrylamidopropyltrimethylammonium chloride) co-poly (4-vinylbiphenyl) (MAPTAC co-VBPh)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyltrimethylammonium chloride (MAPTAC) (10.49 g of a 50% aqueous solution, 0.0475 mol), 4-vinylbiphenyl (VBPh) (9.01 g, 0.050 mol), divinyl benzene crosslinking co-monomer (1.47 g), 2-propanol (150 mL), and the polymerization initiator AIBN (0.25 g). The resulting mixture contained insoluble VBPh which dissolved upon warming. Next, the reaction mixture was heated to 70° C. while degassing with nitrogen. After a short period of time, the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 70° C. for 24 hours and then filtered while hot.
The resulting polymer was washed on the filtration funnel with isopropanol, and then immediately slurried in 200 mL of methanol, followed by stirring for 1 hour. The polymer slurry was then filtered, after which the methanol slurry procedure was repeated. Next, the polymer was slurried two times using 200 mL of water each time. The resulting mixture was then filtered and the filter cake slurried two times with methanol using 200 mL of methanol each time. The resulting mixture was then filtered and vacuum dried to afford 9.59 g of copolymer.
29. Preparation of Poly (methacrylamidopropyltrimethylammonium chloride) co-poly (4-vinylanisole) (MAPTAC co-VA)
To a 1000 mL, three-necked, round-bottomed flask was added the following: methacrylamidopropyltrimethylammonium chloride (MAPTAC) (10.49 g of a 50% aqueous solution, 0.0475 tool), 4-4-vinylanisole (VA) (6.71 g, 0,050 tool), divinyl benzene crosslinking co-monomer (1.30 g), 2-propanol (200 mL), and the polymerization initiator AIBN (0.40 g). The resulting clear solution was heated to 70° C. while degassing with nitrogen. After several hours the solution began to turn cloudy, indicating that polymerization was proceeding. The reaction was maintained at 70° C. for 36 hours and then allowed to cool to room temperature.
The resulting polymer was filtered and washed on the filtration funnel with isopropanol, and then immediately slurried in 200 mL of methanol, followed by stirring for 1 hour. The polymer slurry was then filtered and slurried two times using 200 mL of water each time. The resulting mixture was then filtered and the filter cake slurried in 200 mL of methanol, after which it was slurried in 200 mL of isopropanol. The resulting mixture was then filtered and vacuum dried to afford 5.19 g of copolymer.
30. Preparation of Poly (N-(4-methylstyrene)-N'-(3-trimethylammonio-2-hydroxypropylchloride)piperazine)
The first step in the reaction is the preparation of 4-(piperazinylmethyl)styrene.
To a 500 mL flask was added vinylbenzyl chloride (7.63 g, 0.050 mol), piperazine (8.61 g, 0.100 mol), and isopropanol (50 mL). The resulting solution was heated to 70° C. for 45 minutes and then cooled slowly to room temperature to form a slurry of crystalline material. The slurry was refrigerated for about three hours and then filtered. The solid piperazine hydrochloride salt was vacuum dried and then weighed (5.55 g) and discarded. The mother liquor was concentrated to about 25 mL on a rotary evaporator and ethyl acetate (50 mL) was added). The resulting mixture was refrigerated for about 10 minutes, after which a second crop of piperazine hydrochloride was filtered off and discarded. The mother liquor was then evaporated to dryness on a rotary evaporator to afford 10.35 g of crude 4-(piperazinylmethyl)styrene which was used without further purification to prepare N-(4-methylstyrene)-N'-(3-trimethylammonio-2-hydroxypropyl chloride)piperazine as follows.
To a 500 mL flask was added 4-(piperazinylmethyl)styrene (10.35 g, about 0.45 mol), glycidyl trimethyl ammonium chloride (7.58 g, 0.045 mol), and isopropanol (50 mL). The resulting mixture was heated to 60° C. and stirred for 20 hours, after which it was cooled to room temperature and used for polymerization reactions without further purification as follows.
To 0.40 mol of N-(4-methylstyrene)-N'-(3-trimethylammonio-2-hydroxypropyl chloride)piperazine in 100 mL of isopropanol was added divinyl benzene crosslinking co-monomer (0.93 g). The resulting solution was degassed with nitrogen and then the polymerization initiator AIBN (0.20 g) was added. The temperature was raised to 70° C. with continued nitrogen degassing and held there for three hours, at which point a large quantity of cross-linked polymer had precipitated. The mixture was then cooled to 40° C. and filtered.
The resulting polymer was washed on the filtration funnel with isopropanol and then immediately slurried in 200 mL of methanol, after which it was stirred for 1 hour. The polymer slurry was then filtered and the methanol slurry procedure repeated. The resulting polymer was then slurried two times in 200 mL of water each time, followed by filtration. The filter cake was slurried two times in 200 mL of methanol each time. Filtration and vacuum drying afforded 7.90 g of polymer.
31. Preparation of Poly (N-(4-methylstyrene)-N'-(3-trimethylammonio-2-hydroxypropyl)piperazine), co -polystyrene
To 0,022 mol of N-(4-methylstyrene)-N'-(3-trimethylammonio-2-hydroxypropyl)piperazine (prepared as described in Example 30) was added styrene co-monomer (2.29 g, 0,022 mol) and divinyl benzene crosslinking co-monomer (0.50 g, 0,004 mol). The resulting solution was degassed with nitrogen, after which the polymerization initiator AIBN (0.3 g) was added. The temperature was raised to 70° C. with continued nitrogen degassing and held there for four hours, at which point a large quantity of crosslinked polymer has precipitated. Twenty five mL's of additional isopropanol was then added and heating continued for another 19 hours, after which the mixture was cooled to room temperature and filtered to yield solid polymer.
The resulting polymer was filtered and washed on the filtration funnel with methanol and then immediately slurried in 200 mL of methanol. The mixture was stirred for 0.5 hour, after which it was filtered and the polymer slurried two times using 250 mL of water each time. Next, the mixture was filtered and the filter cake was slurried in 200 mL of methanol, filtered, and then slurried in 200 mL of isopropanol. Filtration and vacuum drying afforded 4.98 g of copolymer.
A copolymer containing a 2:1 molar ration of styrene to quaternary amine monomer was also prepared in an analogous manner.
32. Preparation of Poly (N-(3-trimethylammonio-2-hydroxypropylchloride)-4-aminostyrene)
The first step is the preparation of 4-aminomethylstyrene as follows.
To a 250 mL flask was added vinylbenzyl chloride (7.63 g, 0,050 mol), concentrated aqueous ammonia (9.8 mL), and isopropanol (40 mL). The mixture was stirred for one week, at which point a large quantity of crystalline material (ammonium chloride) had precipitated. The solid was filtered off and washed with isopropanol. The mother liquor was evaporated on a rotary evaporator until no ammonia odor could be detected. Isopropanol (50 mL) was then added, and the mixture refrigerated for several hours. Following refrigeration, ammonium chloride which had precipitated was filtered off to yield 4-aminomethylstyrene which was used without further purification.
To a 500 mL flask was added 4-aminomethylstyrene (0,050 mol), glycidyl trimethylammonium chloride (7.62 g, 0,050 mol), water (about 2 mL) to effect solution, and divinylbenzene crosslinking co-monomer (0.98 g). The resulting solution was heated at 70° C. for 5 hours, after which a small amount of water (about 5-10 mL) was added to dissolve some precipitated salts. The polymerization initiator AIBN (0.20 g) was added while concurrently degassing the solution with nitrogen. The reaction mixture became very thick with polymer, requiring the addition of isopropanol to permit stirring.
After stirring for about 16 hours at 70°0 C., the mixture was cooled to room temperature and filtered. The resulting polymer was washed on the filtration funnel with methanol and then immediately slurried in 200 mL of methanol. The resulting mixture was stirred for 1 hour, after which the polymer slurry was filtered and the methanol slurry procedure repeated. The polymer was then slurried two times in 200 mL of water each time, after which the mixture was filtered and the filter cake slurried in 200 mL of methanol. Filtration and vacuum drying afforded 8.68 g of polymer.
33. Alkylation of Poly(dimethylaminopropylmethacrylamide) crosslinked with methylenebismethacrylamide with 1-iodooctane alkylating agent
Poly(dimethylaminopropylmethacrylamide) crosslinked with methylenebismethacrylamide prepared as described in Example 5 (1.0 g) was suspended in methanol (100 mL) and sodium hydroxide (0.2 g) was added. After stirring for 15 minutes, 1-iodooctane (1.92 mL) was added and the mixture stirred at 60° C. for 20 hours. The mixture was then cooled and the solid filtered off. Next, the solid was washed by suspending it in isopropanol (500 mL), after which it was stirred for 1 hour and then collected by filtration. The wash procedure was then repeated twice using aqueous sodium chloride (500 mL of a 1M solution), twice with water (500 mL), and once with isopropanol (500 mL) before drying in a vacuum oven at 50° C. for 24 hours to yield 0.1 g of alkylated product.
34. Alkylation of Poly(dimethylaminopropylacrylamide) crosslinked with methylenebismethacrylamide with 1-iodooctane alkylating agent
Poly(dimethylaminopropylacrylamide) crosslinked with methylenebismethacrylamide prepared as described in Example 4 (10 g) was alkylated according to the procedure described in Example 33. The procedure yielded 2.95 g of alkylated product.
35. Preparation of Poly (2-(methacroylamido)ethyltrimethylammonium iodide) co-polystyrene
The first step is the preparation of 2-(N',N'-dimethylamino)-N-ethyl methacrylamide hydrochloride as follows.
To a 1000 mL flask was added methacryloyl chloride (52.3 g, 0.5 mol) and tetrahydrofuran (300 mL). The solution was cooled to less than 10° C. after which a solution of N,N-dimethylaminoethylamine (30.5 g, 0.35 mol) in tetrahydrofuran (100 mL) was added dropwise while maintaining the temperature at 8°-10° C. When the addition was complete, the mixture was filtered, washed with cold tetrahydrofuran, and vacuum dried to yield 65.69 g of 2-(N', N'-dimethylamino)-N-ethyl methacrylamide hydrochloride
The next step was the preparation of 2-(methacryloylamido)ethyltrimethylammonium iodide as follows.
Potassium hydroxide (15.4 g, 0.24 mol) and methanol (240 mL) were added to a 500 mL flask, and the mixture stirred to effect complete dissolution of the potassium hydroxide To the solution was added 2-(N', N'-dimethylamino)-N-ethyl methacrylamide hydrochloride (46.35 g, 0.24 mol) and the resulting mixture stirred for 0.5 hour. The mixture was then filtered to remove potassium chloride and the filtrate was concentrated on a rotary evaporator. Isopropanol (400 mL) and methyl iodide (18.7 mL, 42.6 g, 0.30 mol) were added to the concentrated filtrate and the mixture stirred at room temperature overnight. In the morning, the solid product was filtered off, washed with isopropanol, and vacuum dried to yield 61.08 g of 2-(methacryloylamido)ethyltrimethylammonium iodide as a white crystalline solid.
Next, 2-(methacryloylamido)ethyltrimethylammonium iodide (12.24 g, 0.050 mol), styrene (5.2 g, 0.050 mol), divinylbenzene crosslinking co-monomer (0.65 g, 0.005 mol), isopropanol (150 mL), water (20 mL), and the polymerization initiator AIBN (0.4 g) were added to a 1000 mL flask and the resulting solution degassed with nitrogen while heating to 70° C. The solution was then stirred for 24 hours at 70° C. under nitrogen, after which it was cooled to room temperature. At this point, the solvent was decanted and 200 mL of methanol added to the flask to create a slurry which was stirred overnight. The product was then filtered and added to a blender with 500 mL of water. The resulting mixture was blended for 15 minutes and then filtered. The remaining solid material was washed sequentially with water (200 mL) and methanol (200 mL). Filtration and vacuum drying yielded 3.22 g of the title polymer.
Testing of Polymers
A. Preparation of Artificial Intestinal Fluid Test Procedure No. 1
Sodium carbonate (1.27 g) and sodium chloride (1.87 g) were dissolved in 400 mL of distilled water. To this solution was added a mixture of purified bile acids, consisting of taurocholic acid (0.138 g, 0.24 mmol), glycocholic acid (0.292 g, 0.60 mmol), glycodeoxycholic acid (0.085 mmol, 0.18 mmol) and glycochenodeoxycholic acid (0.085 mmol, 0.18 mmol). The pH of the solution was adjusted to 7.20 with acetic acid. This solution was used for the testing of the various polymers. The total bile salt concentration in this solution is 3 millimolar, a concentration approximately equal to that found in normal physiological solutions in the duodenum.
Polymers were tested as follows.
To a 40 mL centrifuge tube was added 0.25 g of polymer and 20 mL of the artificial small fluid prepared as described above. The mixture was stirred in a water bath maintained at 37° C. for three hours. The mixture was then centrifuged and the supernatant liquid, being slightly cloudy, was filtered. The filtrate was analyzed for total 3-hydroxy steroid content by an enzymatic assay using 3a-hydroxy steroid dehydrogenase, as described below.
Test Procedure No. 2
Sodium carbonate (1.27 g) and sodium chloride (1.87 g) were dissolved in 400 mL of distilled water. To this solution was added either glycocholic acid (1.95 g, 4.0 mmol) or glycochenodeoxycholic acid (1.89 g, 4.0 mmol) to make a 10 mM solution. The pH of the solution was adjusted to 6.8 with acetic acid. These stock solutions were used for the testing of the various polymers.
Polymers were tested as follows.
To a 14 mL centrifuge tube was added 10 mg of polymer and 10 mL of a bile salt solution in concentrations ranging from 0.1-10 mM prepared from 10 mM stock solution (prepared as described above) and buffer without bile salt in the appropriate amount. The mixture was stirred in a water bath maintained at 37° C. for three hours. The mixture was then filtered. The filtrate was analyzed for total 3-hydroxy steroid content by an enzymatic assay using 3a-hydroxy steroid dehydrogenase, as described below.
Enzymatic Assay for Total Bile Salt Content
Four stock solutions were prepared.
Solution 1. Tris-HCl buffer, containing 0.133M Tris, 0.666 mM EDTA at pH 9.5.
Solution 2. Hydrazine hydrate solution, containing 1M hydrazine hydrate at pH 9.5.
Solution 3. NAD+solution, containing 7 mM NAD+ at pH 7.0.
Solution 4. HSD solution, containing 2 units/mL in Tris-HCl buffer (0.03M Tris, 1 mM EDTA) at pH 7.2.
To a 3 mL cuvette was added 1.5 mL of Solution 1, 1.0 mL of Solution 2, 0.3 mL of Solution 3, 0.1 mL of Solution 4 and 0.1 mL of supernatant/filtrate from a polymer test as described above. The solution was placed in a UV-VIS spectrophotometer and the absorbance (O.D.) of NADH at 340 nm was measured. The bile salt concentration was determined from a calibration curve prepared from dilutions of the artificial intestinal fluid prepared as described above.
All of the polymers previously described were tested in one or both of the above tests and all were efficacious in removing bile salts from the artificial intestinal fluid. Use
The polymers according to the invention may be administered orally to a patient in a dosage of about 1 mg/kg/day to about 10 g/kg/day; the particular dosage will depend on the individual patient (e.g., the patient's weight and the extent of bile salt removal required). The polymer may be administrated either in hydrated or dehydrated form, and may be flavored if necessary to enhance patient acceptability; additional ingredients such as artificial coloring agents may be added as well.
Examples of suitable forms for administration include pills, tablets, capsules, and powders (for sprinkling on food). The pill, tablet, capsule, or powder can be coated with a substance capable of protecting the composition from the gastric acid in the patient's stomach for a period of time sufficient to allow the composition to pass undisintegrated into the patient's small intestine. The polymer may be administered alone or in combination with a pharmaceutically acceptable carrier substance, e.g., magnesium carbonate, lactose, or a phospholipid with which the polymer can form a micelle.
Other embodiments are within the following claims. | A method for removing bile salts from a patient by ion exchange by administering to the patient a therapeutically effective amount of one or more highly crosslinked polymers characterized by a repeat unit having the formula ##STR1## or copolymer thereof, where n is an integer; R 1 is H or a C 1 -C 8 alkyl group; M is ##STR2## or --Z--R 2 ; Z is O, NR 3 , S, or (CH 2 ) m ; m=0-10; R 3 is H or a C 1 -C 8 alkyl group; and R 2 is ##STR3## where p=0-10, and each R 4 , R 5 , and R 6 , independently, is H, a C 1 -C 8 alkyl group, or an aryl group, the polymers being non-toxic and stable once ingested. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of International application No. PCT/JP2016/066559, filed on Jun. 3, 2016, which claims priority to Japanese Patent Application No. 2015-124772, filed on Jun. 22, 2015, the entire contents of each of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to a filtration filter that filters a filtration object in fluid.
BACKGROUND ART
[0003] A cell trapping system has recently been disclosed as a usage example of a filter that filters a filtration object in fluid (see, for example, International Publication No. 2015/019889). In this cell trapping system, a filter for trapping cells is fitted in a tensioned state between a lid member and a storage member. Cells are trapped by causing fluid containing the cells to pass through the filter while the filer is in the tensioned state.
SUMMARY OF INVENTION
[0004] Because the filter of the forgoing cell trapping system is held in the tensioned state, when the fluid passes through the filter, the filter is broken by stress applied thereto.
[0005] The present invention solves this problem by preferably holding the filter in a non-tensioned state and reducing the forces applied to the filter.
[0006] In accordance with a preferred embodiment of the invention, the filter includes a porous film including a central film portion having a plurality of through holes and an outer edge portion adjacent to the central film portion. The porous film portion lies in a flat plane in the absence of a force being applied to the central portion of the central film portion. A frame holds the outer edge portion of the porous film in such a manner that when a force is applied to the central film portion in a first direction, the central film portion moves in the first direction relative to the flat plane and the outer edge portion moves in a second direction, opposite to the first direction, relative to the flat plane.
[0007] The porous film is preferably made of metal. The outer edge portion can have a holding hole and the frame can have a first projection extending through the holding hole. The diameter and/or shape of the holding hole allows the outer edge portion to move in the second direction. The diameter of the first projection is preferably larger than a diameter of the holding hole and has a conical shape.
[0008] In an alternative embodiment, the frame has a recess that receives the outer edge portion. A dimension of the recess in a direction perpendicular to the flat plane is larger than a thickness of the outer edge portion in the direction perpendicular to the flat plane. The recess defines a fulcrum about which the porous film pivots when the force is applied to the central film portion. The frame preferably prevents the porous film from moving along the plane when it is bent by the force applied to the central film portion.
[0009] The recess preferably has first and second opposed surfaces which are spaced apart from one another in a direction perpendicular to the flat plane. The central film portion is preferably circular in shape and has a center. The length of the first and second opposed surfaces, as measured along a direction parallel to the flat plane, can be the same or different.
[0010] In one embodiment, the first and second flat surfaces terminate at first and second circular openings, respectively, the first circular opening being larger than the second circular opening.
[0011] In another embodiment, the frame includes one or more support surfaces located at respective positions spaced from flat plane, each support surface limiting the amount that the central film portion can move in response to the application of an external force to the central film portion in the direction of the support surfaces. The one more support surfaces can include a plurality of projections.
[0012] In this embodiment, central film portion is preferably circular in shape and has a center. Each of the respective projections is a respective distance from the center of the central film portion. Each of the respective projections is also spaced from the flat plane by a respective distance as measured in a direction perpendicular to the flat plane. The distance that a respective projection is spaced from the flat plane decreases as a function of the distance of the respective projection from the center of the central film portion such that respective projections which are closer to the center of the central film portion are spaced further away from the flat plane that respective projections which are further from the center of the central film portion.
[0013] It is possible for the one or more support surfaces to come into contact with a crosspiece of the central film portion when a fluid to be filtered passes through the central film portion.
[0014] According to the present invention, it is possible to provide a filter that can suppress breakage of the filter by relaxing the stress applied to the filter.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is a schematic structural view of a filtration filter according to a first embodiment of the present invention.
[0016] FIG. 2 is a cross-sectional view of the filtration filter, taken along line A-A of FIG. 1 .
[0017] FIG. 3 is a schematic view of a part of a film portion in a porous film according to the first embodiment of the present invention.
[0018] FIG. 4 is a schematic view of the part of the film portion of FIG. 3 , when viewed from the thickness direction.
[0019] FIG. 5 illustrates the motion of the filtration filter according to the first embodiment of the present invention during passage of liquid.
[0020] FIG. 6 illustrates the motion of a modification of the filtration filter according to the first embodiment of the present invention during passage of the liquid.
[0021] FIG. 7 is a schematic structural view of a filtration filter according to a second embodiment of the present invention.
[0022] FIG. 8 illustrates the filtration filter according to the second embodiment of the present invention during passage of liquid.
[0023] FIG. 9 is a schematic structural view of a filtration filter according to a third embodiment of the present invention.
[0024] FIG. 10 is a schematic structural view of a frame in the third embodiment of the present invention.
[0025] FIG. 11 illustrates the filtration filter according to the third embodiment of the present invention during passage of liquid.
[0026] FIG. 12 is a schematic structural view of another filtration filter according to the third embodiment of the present invention.
[0027] FIG. 13 is a schematic structural view of another frame in the third embodiment of the present invention.
[0028] FIG. 14A illustrates a modification of a support part in the third embodiment of the present invention.
[0029] FIG. 14B illustrates a modification of the support part in the third embodiment of the present invention.
[0030] FIG. 14C illustrates a modification of the support part in the third embodiment of the present invention.
[0031] FIG. 14D illustrates a modification of the support part in the third embodiment of the present invention.
[0032] FIG. 14E illustrates a modification of the support part in the third embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] Embodiments of the present invention will be described below with reference to the accompanying drawings. In the drawings, elements are exaggeratedly illustrated for easy explanation.
First Embodiment
[Overall Structure]
[0034] FIG. 1 is a schematic view of a filtration filter 100 A according to a first embodiment of the present invention. FIG. 2 is a cross-sectional view of the filtration filter 100 A, taken along line A-A of FIG. 1 . As illustrated in FIGS. 1 and 2 , the filtration filter 100 A includes a porous film 10 that separates a filtration object contained in fluid which is passed through the porous film, and a frame 20 that holds an edge portion of the porous film 10 . The porous film 10 is composed of a film portion 12 having a plurality of through holes 11 , and an edge portion 13 adjacent to the film portion 12 . In the first embodiment, the edge portion 13 ( FIG. 2 ) of the porous film 10 is held by a recess 21 of the frame 20 so that it moves in the thickness direction of the porous film 10 .
[0035] Fluid containing a filtration object is passed through the porous film 10 and the filtration filter 100 A separates the filtration object from the fluid. In this description, the term “filtration object” refers to an object to be filtered by the porous film 10 . In the first embodiment, a biological substance is preferably used as the filtration object, and liquid is preferably used as the fluid.
[0036] In this description, the term “biological substance” refers to a substance derived from organisms, for example, a cell (eukaryote), a bacterium ( eubacterium ), and a virus. Examples of the cell (eukaryote) include an ovum, a sperm, an induced pluripotent stem cell (iPS cell), an ES cell, a stem cell, a mesenchymal stem cell, a mononuclear cell, a single cell, a cell mass, a floating cell, an adherent cell, a nerve cell, a white blood cell, a lymphocyte, a regeneration medical cell, a self-cell, a cancer cell, a circulating tumor cell (CTC), HL-60, HELA, and germs. Examples of the bacterium ( eubacterium ) include a gram-positive bacterium, a gram-negative bacterium, an escherichia coli , and a tubercle bacillus . Examples of the virus include a DNA virus, an RNA virus, a rotavirus, an (avian) influenza virus, a yellow fever virus, a dengue fever virus, an encephalitis virus, a hemorrhagic fever virus, and an immunodeficiency virus. In the first embodiment, the filtration filter 100 A is excellent in separating, especially, an induced pluripotent stem cell (iPS cell), an ES cell, a stem cell, and a circulating tumor cell (CTC) from the liquid.
<Porous Film>
[0037] The porous film 10 is a porous film that separates a biological substance from a fluid. The porous film 10 is preferably a metallic thin film composed of a film portion 12 having a plurality of through holes 11 and an edge portion 13 adjacent to the film portion 12 . As illustrated in FIG. 1 , in the first embodiment, the porous film 10 is formed by a circular metal mesh and includes a pair of opposed principal surfaces and a plurality of through holes 11 penetrating both principal surfaces of the film portion 12 . The plurality of through holes 11 may be periodically arranged all over the principal surfaces of the film portion 12 . For example, the porous film 10 may be made of Ni, the dimensions of the porous film 10 may be 6 mm in diameter and 1.2 μm in thickness. The thickness of the porous film 10 is preferably within the range of 0.5 to 100 μm. The void ratio of the porous film is preferably within the range of 10% to 90%. The void ratio (i.e., the ratio of the area of the holes to the area of the principal surface (including the holes) of the porous film. is more preferably within the range of 20% to 50%. This structure can allow the porous film 10 to be easily bent when the fluid containing the filtration object passes through the porous film 10 and can restrict the porous film 10 from being bent when the fluid does not pass through the porous film 10 . The material of the porous film 10 may be gold, silver, copper, platinum, iron, nickel, chromium, stainless steel, palladium, titanium, or an alloy of these materials. In particular, when the biological substance is trapped, gold, nickel, stainless steel, or titanium is preferably used from the viewpoint of biocompatibility with the biological substance. The material of the porous film 10 may be an elastic material having a Young's modulus of 1 GP or more.
[0038] FIG. 3 is a schematic structural view of a part of the film portion 12 formed by a two-dimensional periodic structure. In FIG. 3 , the X, Y, and Z directions respectively represent the longitudinal direction, the lateral direction, and the thickness direction of the structure. FIG. 4 illustrates the part of the film portion 12 shown in FIG. 3 , when viewed from the Z-direction. As illustrated in FIGS. 3 and 4 , the film portion 12 may be a plate-shaped structure (i.e., a flat structure) in which a plurality of through holes 11 are arranged at regular intervals and in a matrix. The film portion 12 is a plate-shaped structure in which a plurality of square through holes 11 are provided when viewed from the Z-direction on the principal surface side. The plural through holes 11 are provided at regular intervals in two arrangement directions parallel to the sides of squares, that is, in the X-direction and the Y-direction in FIG. 3 . The shape of the through holes 11 is not limited to the square shape, but may be, for example, a rectangular shape, a circular shape, or an elliptic shape. Also, the arrangement of the holes is not limited to the square lattice arrangement, but may be, for example, a rectangular arrangement in which the intervals are not equal between the two arrangement directions as long as the arrangement is the quadrangular arrangement, or may be, for example, a triangular lattice arrangement or a quasiperiodic arrangement.
[0039] The shape and dimensions of the through holes 11 in the film portion 12 are appropriately designed according to the size and shape of the biological (or other) substance to be filtered. For example, the through holes 11 are square when viewed from the principal surface side of the film portion 12 , that is, viewed from the Z-direction, and are designed to be within the range of 0.1 to 500 μm in length and within the range of 0.1 to 500 μm in width. The interval between the through holes 11 is, for example, within the range of 1 to 10 times of the size of the through holes 11 , and more preferably 3 times or less of the size of the through holes 11 . Alternatively, the aperture ratio is preferably 10% or more.
<Frame>
[0040] The frame 20 holds the edge portion 13 of the porous film 10 . As illustrated in FIG. 1 , in the first embodiment, the frame 20 is formed by an annular member. As illustrated in FIG. 2 , the frame 20 has a recess 21 opening toward the porous film 10 to hold the edge portion 13 of the porous film 10 . The dimension of the recess 21 in the thickness direction of the frame 20 is designed to be larger than the thickness of the edge portion 13 . Also, the dimension of the recess 21 in the thickness direction of the frame 20 is designed so that a distal end of the edge portion 13 of the porous film 10 comes into contact with an upper inner wall of the recess 21 and a part of a lower surface of the edge portion 13 comes into contact with a lower inner wall of the recess 21 when the fluid passes through the porous film 10 . By thus designing the dimensions of the recess 21 , the upper inner wall and the lower inner wall of the recess 21 can hold the edge portion 13 of the porous film 10 when the film portion 12 is bent.
[0041] For example, the dimension of the recess 21 in the thickness direction of the frame 20 is designed to be larger than 100% and smaller than or equal to 500% of the thickness of the edge portion 13 . More preferably, the dimension of the recess 21 in the thickness direction of the frame 20 is designed to be within the range of 200% to 400% of the thickness of the edge portion 13 . This can form a gap that permits the edge portion 13 of the porous film 10 to move in the thickness direction of the porous film 10 while at the same time preventing the porous film 10 from coming out of the frame 20 . In this way, the frame 20 holds the edge portion 13 of the porous film 10 in a state in which the porous film 10 is not fixed and no tension is applied thereto. The frame 20 does not always need to hold the entire circumference of the edge portion 13 of the porous film 10 , and for example, may hold two opposed portions of the edge portion 13 or hold a plurality of spaced, preferably equally spaced, portions of the edge portion 13 .
[0042] In the first embodiment, the frame 20 has first and second frames (these frames are shown combined as a single from in FIGS. 1 and 2 ). In the frame 20 of the first embodiment, after the porous film 10 is inserted into the first frame, the second frame is fitted to the first frame. This allows the porous film 10 to be held inside the frame 20 .
[Motion of Filtration Filter During Passage of Liquid]
[0043] FIG. 5 illustrates the motion of the filtration filter 100 A during passage of liquid through the filtration filter 100 A. A white arrow denoted by reference numeral 50 in FIG. 5 shows the flow of the liquid from the upstream side to the downstream side of the filtration filter 100 A. As illustrated in FIG. 5 , in the filtration filter 100 A, when liquid containing a biological substance passes through the porous film 10 in the direction 50 , stress in the direction 50 is applied to a center portion of the film portion 12 . Because the pivot (fulcrum) defined at the bottom inner edges of the recess 21 , the edge portion 13 of the porous film 10 moves in a direction opposite from the direction 50 inside the recess 21 . Specifically, the edge portion 13 of the porous film 10 is curved (bent) and raised in the direction opposite from the direction 50 at an angle to the center portion of the film portion 12 . Since the edge portion 13 of the porous film 10 can thus move in the thickness direction of the porous film 10 without being fixed, the center portion of the porous film 10 can be bent in the direction 50 opposite from the direction in which the edge portion 13 moves.
[0044] The motion of the edge portion 13 of the porous film 10 is restricted by the upper wall surfaces of the recess 21 . Specifically, when the edge portion 13 of the porous film 10 is raised in the direction opposite from the direction 50 , the distal end of the edge portion 13 of the porous film 10 comes into contact with an upper inner wall of the recess 21 , and another part of the edge portion 13 comes into contact with an inner edge of the lower inner wall of the recess 21 . That is, the distal end of the edge portion 13 is supported by the upper inner wall of the recess 21 , whereas the part of the lower surface of the edge portion 13 is supported by the lower inner wall of the recess 21 . For this reason, the edge portion 13 of the porous film 10 does not come out of the recess 21 , but is held by the frame 20 . The amount that the film portion 12 can bend depends on the dimension of the recess 21 in the thickness direction of the frame 20 . Specifically, the bending amount depends on the dimension of the gap between the upper wall of the recess 21 and the edge portion 13 . As this gap increases, the amount the edge portion 13 of the porous film 10 can move when the liquid to be filtered passes through the film portion 10 increases. during passage of the liquid increases. Hence, the bending amount of the film portion 12 increases.
[0045] In this way, when the liquid passes through the filtration filter 100 A, the film portion 12 is bent in the direction 50 in which the liquid flows. This can reduce the force of the liquid in the direction perpendicular to the film portion 12 , and relax the stress applied to the film portion 12 . That is, in the filtration filter 100 A, the force in the direction 50 , in which the liquid flows, can be released from the film portion 12 and the stress applied to the film portion 12 can be relaxed by bending the film portion 12 . Also, when the liquid does not pass through the filtration filter 100 A, the film portion 12 is held in an unbent state by the frame 20 , as illustrated in FIG. 2 .
[0046] As described above, in the filtration filter 100 A, when the liquid containing the biological substance passes through the porous film 10 , the biological substance is separated from the liquid while the film portion 12 is bent and the stress applied to the film portion 12 is reduced.
[Effects]
[0047] According to the filtration filter 100 A of the first embodiment, the following effects can be achieved.
[0048] In the filtration filter 100 A, the recess 21 of the frame 20 holds the edge portion 13 of the porous film 10 so that the edge portion 13 moves in the thickness direction of the porous film 10 . That is, the frame 20 does not fix the porous film 10 , but holds the porous film 10 under no tension. According to this structure, the film portion 12 can be bent in the direction 50 in which the liquid flows when the liquid passes through the filtration filter 100 A. As a result, when the liquid passes through the filtration filter 100 A, the stress applied to the film portion 12 can be relaxed by bending the film portion 12 , and this can suppress breakage of the film portion 12 .
[0049] In the filtration filter 100 A, the dimension of the recess 21 in the thickness direction of the frame 20 is designed to be larger than the thickness of the edge portion 13 of the porous film 10 . This structure can form, inside the recess 21 , the gap that permits the edge portion 13 of the porous film 10 to move in the thickness direction of the porous film 10 . Since the edge portion 13 of the porous film 10 moves in the thickness direction of the porous film 10 inside this gap, the film portion 12 can be moved in the direction opposite from the direction in which the edge portion 13 moves. This allows the film portion 12 to be bent reliably. Also, in the filtration filter 100 A, the bending amount of the film portion 12 can be controlled by adjusting the dimension of the recess 21 in the thickness direction of the frame 20 .
[0050] In the filtration filter 100 A, when the liquid does not pass through the porous film 10 , the film portion 12 is held in an unbent state. In this way, in the filtration filter 100 A, the film portion 12 is bent when the liquid passes. This can enhance handleability of the user. For example, when the filtration filter 100 A is mounted in a filtration device, the user can mount the filtration filter 100 A while holding only the frame 20 . At this time, the film portion 12 is held in an unbent state. For this reason, the filtration filter 100 A can suppress the user from erroneously touching the film portion 12 and can reduce the risk of soiling the film portion 12 , compared with the filtration filter in which the film portion 12 is always bent.
[0051] The porous film 10 is preferably made of metal. This structure can further suppress breakage of the porous film 10 . Also, when the liquid passes through the film portion 12 , since the through holes 11 hardly deform, the biological substance can be suppressed from passing through the film portion 12 owing to deformation of the through holes 11 .
[0052] While the terms “filtration object” and “fluid” have been respectively described as, for example, the biological substance and the liquid in the first embodiment, they are not limited thereto. The fluid may be gas. The filtration object may be, for example, particulate matter (PM 10, SPM, or PM 2.5).
[0053] While the metallic thin film is used as the porous film 10 in the first embodiment, the porous film 10 is not limited thereto. For example, the porous film 10 may be a film formed, for example, by a membrane, filter paper, or nonwoven fabric.
[0054] FIG. 6 illustrates the motion of a modification of the filtration filter 100 A according to the first embodiment. As illustrated in FIG. 6 , a frame 20 a may be structured in a manner such that the area of a lower inner wall of a recess 21 is larger than the area of an upper inner wall of the recess 21 . This structure increases the area in which a lower surface of an edge portion 13 of a porous film 10 is in contact with the lower inner wall of the recess 21 . Hence, when a film portion 12 is bent, the lower surface of the edge portion 13 is easily supported by the lower inner wall of the recess 21 .
[0055] While the frame 20 has two frames in the first embodiment, the invention is not so limited. For example, the frame 20 may have two or more frames. Alternatively, the frame 20 may be formed by a single component.
Second Embodiment
[Overall Structure]
[0056] A filtration filter according to a second embodiment of the present invention will be described with reference to FIG. 7 .
[0057] FIG. 7 illustrates a schematic structure of a filtration filter 100 B according to a second embodiment. In the second embodiment, differences from the first embodiment will be mainly described. In the second embodiment, structures identical or equivalent to those of the first embodiment are denoted by the same reference numerals. Also, in the second embodiment, descriptions overlapping with those of the first embodiment are skipped.
[0058] As illustrated in FIG. 7 , the filtration filter 100 B of the second embodiment is different from the filtration filter 100 A of the first embodiment in the structure for holding a porous film 10 . Specifically, an edge portion 13 of the porous film 10 has a holding hole 14 , and a frame 20 has a projection 22 instead of the recess 21 .
<Holding Hole>
[0059] The holding hole 14 is a hole in which the projection 22 is to be inserted, and is provided in the edge portion 13 of the porous film 10 . The holding hole 14 communicates between two opposed principal surfaces of the porous film 10 . The holding hole 14 preferably has a circular shape, when viewed from the principal surface side of the porous film 10 . The diameter of the holding hole 14 is designed to be larger than the diameter of the projection 22 . In the second embodiment, for example, a plurality of holding holes 14 are equally spaced on the concentric edge portion 13 of the porous film 10 , when viewed from the principal surface side of the porous film 10 formed by a circular metal mesh.
<Projection>
[0060] The projection 22 holds the edge portion 13 of the porous film 10 by being inserted in the holding hole 14 of the porous film 10 . The projection 22 projects from an upper surface of the frame 20 in the thickness direction of the frame 20 . In the second embodiment, for example, a plurality of projections 22 are provided at positions corresponding to the holding holes 14 of the porous film 10 .
[0061] The projections 22 may be, for example, conical pins. The diameter of the projections 22 is designed to be smaller than the diameter of the holding holes 14 . That is, the diameter of the holding holes 14 is designed to be larger than the diameter of the projections 22 , and for example, the diameter of the holding holes 14 is designed to be larger than 100% and smaller than or equal to 200% of the diameter of the projections 22 . Thus, when the projections 22 are inserted in the holding holes 14 , gaps that allow the edge portion 13 of the porous film 10 to move in the thickness direction of the porous film 10 can be formed between inner walls of the holding holes 14 and the projections 22 . Also, the height of the projections 22 in the thickness direction of the frame 20 is designed at such a height that the holding holes 14 do not come out of the projections 22 . The height of the projections 22 is appropriately determined according to the dimensions such as the diameter of the holding holes 14 and the diameter of the porous film 10 .
[Motion of Filtration Filter During Passage of Liquid]
[0062] FIG. 8 illustrates the motion of the filtration filter 100 B when a liquid passes there through. A white arrow denoted by reference numeral 50 in FIG. 8 shows the flow of liquid from the upstream side to the downstream side of the filtration filter. As illustrated in FIG. 8 , in the filtration filter 100 B, when liquid containing a biological substance passes through the porous film 10 in the direction 50 , stress in the direction 50 is applied to a center portion of the film portion 12 . At this time, the edge portion 13 of the porous film 10 moves in a direction opposite from the direction 50 along outer walls of the projections 22 inserted in the holding holes 14 . Specifically, the edge portion 13 of the porous film 10 is curved and raised in the direction opposite from the direction 50 at an angle to the center portion of the film portion 12 . Since the edge portion 13 of the porous film 10 can thus move in the thickness direction of the porous film 10 without being fixed, the center portion of the film portion 12 can be bent in the direction 50 .
[0063] When the edge portion 13 of the porous film 10 moves in the direction opposite from the direction 50 , the inner walls of the holding holes 14 are caught by outer walls of the projections 22 and the edge portion 13 of the porous film 10 is held with an angle by the frame 20 . In this way, the projections 22 function as fall-preventing members for the porous film 10 while restricting the movement of the edge portion 13 . The bending amount of the film portion 12 depends on the diameter of the holding holes 14 . Specifically, the bending amount depends on the dimensions of the gaps between the inner walls of the holding holes 14 and the outer walls of the projections 22 . When the gaps increase, the moving amount of the edge portion 13 of the porous film 10 during passage of the liquid increases. Hence, the bending amount of the film portion 12 increases.
[Effects]
[0064] According to the filtration filter 100 B of the second embodiment, the following effects can be achieved.
[0065] In the filtration filter 100 B, the frame 20 holds the porous film 10 with the projections 22 thereof inserted in the holding holes 14 provided in the edge portion 13 of the porous film 10 . Also, since the diameter of the holding holes 14 is larger than the diameter of the projections 22 , when the projections 22 are inserted in the holding holes 14 , gaps can be formed between the inner walls of the holding holes 14 and the projections 22 . Accordingly, when the liquid passes through the filtration filter 100 B, the edge portion 13 of the porous film 10 is moved with an angle in the thickness direction of the porous film 10 and this can bend the film portion 12 in the direction 50 in which the liquid flows. As a result, when the liquid passes through the filtration filter 100 B, the stress applied to the film portion 12 can be relaxed by bending of the film portion 12 and this can suppress breakage of the film portion 12 .
[0066] In the filtration filter 100 B, the bending amount of the film portion 12 can be controlled by adjusting the diameter of the holding holes 14 and the diameter of the projections 22 .
[0067] While the holding holes 14 have a circular shape when viewed from the principal surface side of the porous film 10 in the second embodiment, the shape is not limited thereto. It is only necessary that the holding holes 14 should have such a shape to permit insertion of the projections 22 . The holding holes 14 may have an arbitrary shape such as a triangular shape, a quadrangular shape, a trapezoidal shape, or an elliptic shape. Alternatively, the holding holes 14 may be slots extending toward the center portion of the porous film 10 . When the holding holes 14 are formed as slots extending toward the center portion of the porous film 10 , the movement of the edge portion 13 of the porous film 10 in the directions other than the thickness direction, for example, the movement in the circumferential direction of the porous film 10 can be restricted.
[0068] While the projections 22 are conical pins, for example, in the second embodiment, the shape is not limited thereto. The projections 22 can have any shape as long as they can hold the porous film 10 by being inserted in the holding holes 14 of the porous film 10 while permitting the edge portion 13 of the porous film 10 to move in the thickness direction of the porous film 10 . For example, the projections 22 may be shaped like a triangular prism, a quadrangular prism, or a circular column.
[0069] While the projections 22 are provided on the upper surface of the frame 20 in the second embodiment, the structure is not limited thereto. For example, the projections 22 may be provided inside the recess 21 of the first embodiment. According to this structure, since the recess 21 and the projections 22 can hold the edge portion 13 of the porous film 10 , the porous film 10 can be held while more reliably bending the film portion 12 .
Third Embodiment
[Overall Structure]
[0070] A filtration filter according to a third embodiment of the present invention will be described with reference to FIGS. 9 and 10 .
[0071] FIG. 9 illustrates a schematic structure of a filtration filter 100 C according to the third embodiment. FIG. 10 illustrates a schematic structure of a frame 20 in the third embodiment. In FIG. 10 , the porous film 10 is not illustrated for easy explanation.
[0072] Differences of the third embodiment from the first embodiment will be mainly described. In the third embodiment, structures identical or equivalent to those of the first embodiment are denoted by the same reference numerals. Also, in the third embodiment, descriptions overlapping with those of the first embodiment will be skipped.
[0073] As illustrated in FIGS. 9 and 10 , the filtration filter 100 C of the third embodiment is different from the filtration filter 100 A of the first embodiment in having a support part 30 . The support part 30 supports a bent film portion 12 when liquid passes through the filtration filter 100 C. As illustrated in FIGS. 9 and 10 , the support part 30 is disposed at a position spaced from the principal surface of the film portion 12 in the thickness direction. Specifically, the support part 30 is provided on an inner wall of a frame 20 , and is disposed on the downstream side of the film portion 12 relative to the flow of fluid through the filtration filter. The support part 30 has two plate-shaped members, and is disposed so that the members intersect at a position corresponding to a center portion of the film portion 12 . On a surface of the support part 30 on the side of the film portion 12 , a plurality of projections 31 a , 31 b , 31 c , 31 d , and 31 e are provided.
[0074] As illustrated in FIG. 10 , the projection 31 a is disposed at the position corresponding to the center portion of the film portion 12 , that is, at the position where the two plate-shaped members intersect. The projections 31 b , 31 c , 31 d , and 31 e are disposed at positions at a predetermined distance from the projection 31 a . The plurality of projections 31 a to 31 e are arranged to be in contact with the film portion 12 along the shape of the bent film portion 12 . Specifically, as illustrated in FIG. 9 , the plurality of projections 31 a to 31 e are designed so that the distance between distal ends of the projections 31 a to 31 e and the lower principal surface of the film portion 12 decreases from the center portion toward the outer side portion of the film portion 12 . That is, the height of the projection 31 a in the thickness direction of the film portion 12 is designed to be smaller than the height of the projections 31 b , 31 c , 31 d , and 31 e . The plurality of projections 31 a to 31 e may be conical pins.
[Motion of Filtration Filter During Passage of Liquid]
[0075] FIG. 11 illustrates the motion of the filtration filter 100 C while a liquid (more generally a fluid) is passing through there through. In FIG. 11 , a white arrow denoted by reference numeral 50 in FIG. 11 shows the flow of liquid from the upstream side to the downstream side of the filtration filter. As illustrated in FIG. 11 , when liquid containing a biological substance passes through the film portion 12 of the filtration filter 100 C in the direction 50 , stress in the direction 50 is applied to the center portion of the film portion 12 , and the center portion of the film portion 12 is bent in the direction 50 . The bent film portion 12 comes into contact with the distal ends of the plurality of projections 31 a to 31 e in the support part 30 . In this way, the support part 30 suppresses excessive bending of the film portion 12 .
[0076] The plurality of projections 31 a to 31 e of the support part 30 preferably come into contact with a crosspiece of the film portion 12 when the fluid passes through the film portion 12 . The crosspiece of the film portion 12 refers to a portion of the film portion 12 where the through holes 11 are not provided. According to this structure, the plurality of projections 31 a to 31 e of the support part 30 come into contact with the crosspiece of the film portion 12 and this can restrict bending of the film portion 12 without hindering the flow of the fluid.
[Effects]
[0077] According to the filtration filter 100 C of the third embodiment, the following effects can be achieved.
[0078] In the filtration filter 100 C, the frame 20 is provided with the support part 30 that supports the bent film portion 12 when the liquid passes there through. Also, in the support part 30 , the plurality of projections 31 a to 31 e projecting toward the film portion 12 are arranged to come into contact with the bent film portion 12 . This structure restricts excessive bending of the film portion 12 during passage of the liquid. As a result, stress concentration can be restricted from being caused by excessive bending of the film portion 12 . Further, since the plurality of projections 31 a to 31 e are provided on the surface of the support part 30 , the support part 30 can support the film portion 12 while dispersing the stress applied to the film portion 12 .
[0079] In the filtration filter 100 C, the plurality of projections 31 a to 31 e are designed so that the distance between the distal ends of the projections and the principal surface of the film portion 12 decreases from the center portion toward the outer side portion of the film portion 12 . According to this structure, the plurality of projections 31 a to 31 e come into contact with the film portion 12 along the shape of the film portion 12 bent when the liquid passes. For this reason, the projections 31 a to 31 e can more equally disperse the stress applied to the film portion 12 . As a result, the filtration filter 100 C can reliably suppress breakage of the film portion 12 .
[0080] By using the conical pins as the plurality of projections 31 a to 31 e , the film portion 12 can be supported without hindering the flow of the liquid.
[0081] While the support part 30 is added to the structure of the first embodiment in the structure of the third embodiment, the structure is not so limited. FIG. 12 illustrates a schematic structure of another filtration filter according to the third embodiment. For example, as illustrated in FIG. 12 , the support part 30 may be added to the structure of the second embodiment.
[0082] While the support part 30 has the plurality of projections 31 a to 31 e in the third embodiment, the structure is not so limited. The number of projections can be set at an arbitrary number, for example, according to the size of the film portion 12 . For example, the support part 30 may be structured to have no projection, to have only one projection, or to have more than five projections. FIG. 13 illustrates a schematic structure of another frame 20 in the third embodiment. As illustrated in FIG. 13 , for example, the support part 30 may have one projection 31 a at a position corresponding to the center portion of the film portion 12 . By reducing the number of projections on the support part 30 , the flow of the liquid can be suppressed from being hindered by the projections.
[0083] While the illustrated projections 31 a to 31 e are shaped like conical pins, the structure is not so limited. The support part 30 can have any shape that can come into contact with the film portion 12 bent during passage of the liquid. FIGS. 14A to 14E illustrate modifications of the support part in the third embodiment. As illustrated in FIGS. 14A to 14E , the support part 30 may be a circular support part 32 , an acute triangular support part 33 , a rectangular support part 34 , a square support part 35 , or an inverse-T shaped support part 36 , in a cross section taken along the direction in which the fluid flows. To firmly support the film portion 12 , a support part having a large surface area in contact with the principal surface of the film portion 12 , for example, the support part 32 and the support part 35 respectively having the circular cross section and the square cross section illustrated in FIGS. 14A and 14D may be used. To suppress the support part from hindering the flow of the fluid, a support part having a small surface area in contact with the principal surface of the film portion 12 , for example, the support part 33 , the support part 34 , and the support part 36 respectively having the acute triangular cross section, the rectangular cross section, and the inverse-T shaped cross section illustrated in FIGS. 14B, 14C, and 14E may be used.
[0084] While the present invention has been sufficiently described in conjunction with the preferred embodiments with reference to the accompanying drawings, various modifications and alterations are obvious to those skilled in the art. It should be understood that such modifications and alterations are included in the present invention without departing from the scope of the present invention described in the accompanying claims.
INDUSTRIAL APPLICABILITY
[0085] The present invention relates to the filtration filter, and is excellent in suppressing breakage of the filtration filter when the fluid passes therethrough. For example, the invention can be used for medical diagnosis by taking out cells from a biospecimen and used for environmental measures by trapping PM 2.5 existing in the air.
REFERENCE SIGNS LIST
[0000]
10 : porous film
11 : through hole
12 : film portion
13 : edge portion
14 : holding hole
20 : frame
21 : recess
22 : projection
30 : support part
31 : projection
32 , 33 , 34 , 35 , 36 : support part
50 : direction
100 A, 100 B, 100 C: filtration filter | A filtration filter comprises a porous film including a central film portion having a plurality of through holes and an outer edge portion adjacent to the central film portion. The porous film portion lies in a flat plane in the absence of a force being applied to the central portion of the central film portion. A frame holds the outer edge portion of the porous film in such a manner that when a force is applied to the central film portion in a first direction, the central film portion moves in the first direction relative to the flat plane and the outer edge portion moves in a second direction, opposite to the first direction, relative to the flat plane. In this way stresses applied to the porous film during a filtering operation are reduced. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of U.S. provisional patent application 61/937,418 filed Feb. 7, 2014 of like title and inventorship, the teachings and entire contents which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains generally to mechanical guns and projectors, and more particularly to electrical trigger or releasing mechanisms designed for archery.
2. Description of the Related Art
In the field of archery, a bow has a frame or body that might, for exemplary purposes, comprise a flexible piece of wood or fiber composite. A string spans some portion of the frame. Traditional bow frames may be simple single pieces of wood that are relatively straight or slightly curved, and then bent further under the tension of a string extending generally from tip to tip. The bending of the wood provides a force opposed to the string tension. When the string is drawn, the wood flexes, with the wood acting as a simple spring. Consequently, as the string is drawn, the tension in the string increases progressively. This type of bow, which is still well known and used today, may typically require relatively great draw force. Further, holding the bow at full draw can require great strength and endurance.
There have been many types of bows that have been developed since the advent of the first straight bows, including recurve bows, reflex bows, decurve bows, deflex bows, and the much more recent compound bows. Likewise, there have been many materials used in the fabrication of bows over the years, including but not limited to wood, metal, laminates, and composites. These bows may be designed to have different draw forces and draw lengths. The draw force may range from only a few pounds for a small child's bow to one or even several hundred pounds for very powerful and specialty bows.
A common requirement among many of the bows is the need to manually grasp the bow string when drawing the string, and then to release the string to shoot the arrow. The relatively large draw forces and the relatively small diameter bow string combine to stress the relatively softer and more tender finger tips of the archer, particularly where a bow must be drawn and held for longer time periods. Archers through time have commonly employed various finger coverings such as leather to reduce the direct wear, abrasion, and disruption of circulation in their fingers.
Further, the release of the arrow has also been a form of art. A clean string release will allow the arrow to travel straight and true. However, if the archer slides the string sideways during release, the arrow flight may be slightly distorted, making the shot direction less predictable, reliable, and repeatable.
One slightly divergent technology is that of the crossbow, which addresses several of the challenges that archers may have with other bow types. One advantage of a crossbow is that there is typically some type of nut or other apparatus that is used to hold and eventually release the string. This means that the archer may hold the shot indefinitely without physical fatigue. Further, there is no abrasion to the fingers. In addition, when properly designed, a bolt, arrow, or other projectile will predictably release from the string, since the archer does not directly grasp the string.
Another challenge faced by archers is commonly referred to as target anxiety. This target anxiety may be manifested by an archer flinching or moving just as the string is being released, leading to inaccurate shots. Target anxiety can affect even the most highly skilled and experienced archers.
Over the years, a number of highly skilled artisans have devised various apparatus to effect better holding and release of the bow string. Exemplary mechanical devices, the teachings and contents which are incorporated herein by reference, include: U.S. Pat. No. 2,977,952 by Gabriel et al, entitled “Archery bow trigger”; U.S. Pat. No. 3,800,774 by Troncoso, entitled “Archery bow string release device”; U.S. Pat. No. 3,845,752 by Barner, entitled “Combined bowstring draw and trigger release mechanism for use in archery”; U.S. Pat. No. 4,009,703 by Cunningham, Sr., entitled “Bow string trigger release mechanism”; U.S. Pat. No. 4,672,945 by Carlton, entitled “Archery trigger release mechanism”; U.S. Pat. No. 4,881,516 by Peck, entitled “Adjustable grip and trigger bow string release”; U.S. Pat. No. 6,484,710 by Summers et al, entitled “Archery finger trigger release with cocking slide”; U.S. Pat. No. 8,402,957 by Clark, entitled “Release device for archery”; and 2013/0174820 by Jones, entitled “Archery release”. One of the significant challenges of a string release is the desire for a minimum movement by the archer, with minimal force applied, to effect the string release. While the aforementioned patents represent a significant advancement over the technology in place prior thereto, these prior art mechanical systems simply do not offer sufficiently minimal force and movement by the archer.
Recognizing the need for an improved string release, a few artisans have designed electrical solenoid string releases. Exemplary patents, the teachings and contents which are incorporated herein by reference, include: U.S. Pat. No. 4,674,469 by Peck, entitled “Bow string release”; U.S. Pat. No. 5,243,957 by Neilson, entitled “Archery apparatus”; U.S. Pat. No. 5,494,023 by Kolak, entitled “Bow string releasing apparatus”; and U.S. Pat. No. 5,575,269 by Harklau, entitled “Bowstring release mechanism”. Two additional patents, illustrating electrically driven releases but without a solenoid, the teachings and contents which are incorporated herein by reference, include: U.S. Pat. No. 6,247,467 by Siegfried, entitled “Bowstring release mechanism”; and U.S. Pat. No. 6,766,794 by Bently, entitled “Device for hands-free firing of projectile device”.
Many of the prior art releases have a pivoting member that is locked in place prior to release, and then allowed to rotate freely upon release. Unfortunately, with the substantial force and rapid movement of the bow string, this can and often does lead to a slapping or slamming of the pivotal member when it reaches a stop or rotary limit. Exemplary of the prior art is the Peck '469 patent incorporated by reference herein above. In Peck, the sear 22 has a “j” shape, and pivots about pin 24. When plunger 26 is moved out of the way, sear 22 will rotate with violent force. Not only is this additional sound undesirable, since it can forewarn and thereby spook game, it can lead to undesirable wear and damage of the apparatus over a relatively short period.
Another issue is the relatively large force that is applied by the string to the release. This force will be coupled through linkages that, under load, may bind or wear excessively. Once again, the Peck '469 patent incorporated by reference herein above is exemplary of the prior art. On the longer finger 20 of Peck's sear 22, the bow string will be pulling. This force is offset by a force between the shorter leg of Peck's sear 22 and plunger 26. As may be recognized, this causes significant friction between Peck's sear 22 and plunger 26, the friction making it harder to release plunger 26 and also leading to galling and wear of both Peck's sear 22 and plunger 26. Similar deficiency is found in both Harklau and Kolak.
Further, many of these prior art devices are not automatically resetting. Again referencing the Peck design, the archer must activate the solenoid, pivot the sear 22 into place around the spring, and then release the solenoid. This resetting sequence is an undesirable, unnecessary and challenging test of manual dexterity. Once again, similar deficiency is found in both Harklau and Kolak.
Neilson in FIGS. 13-15 illustrates a different type of string release, using a solenoid and cam to wedge between two pivoting arms. This causes the arms to either open when not wedged, or close when wedged by the solenoid cam. Unfortunately, the greater the draw force, the more likely the string is to accidentally release. Further, not only are manufacturing tolerances an issue, so is wear to the various components, which will worsen the ability of the device to hold a bow string. Consequently, Neilson has the potential for accidental and unintended releases that can be very dangerous in the field.
In addition to the foregoing patents, Webster's New Universal Unabridged Dictionary, Second Edition copyright 1983, is incorporated herein by reference in entirety for the definitions of words and terms used herein.
SUMMARY OF THE INVENTION
In a first manifestation, the invention is a bow string release. A housing anchors a drive cam fixed pivot. A drive cam is rotatable about the drive cam fixed pivot. A linear motor is operatively actuated by a trigger. A reciprocating piston has a first end coupled with and moved by the linear motor, and a second end distal to the first end is adapted to operatively couple with the drive cam and adapted to operatively rotate the drive cam about the drive cam fixed pivot, responsive to the piston first end being moved by the linear motor. A string hook fixed pivot is also anchored to the housing. A string hook is adapted to operatively engage a bow string and transmit a draw force to the bow string. A follower link has a first floating pintle pivotally coupling adjacent a first end to the drive cam and a second floating pintle pivotally coupled adjacent a second end distal to the link first end to the string hook. The string hook is rotated about the string hook fixed pivot responsive to the piston first end being moved by the linear motor.
In a second manifestation, the invention is a bow string release having a housing. A string hook is adapted to operatively engage a bow string and transmit a draw force to the bow string. An electrical power source is coupled with an electrical solenoid having a reciprocating piston and an electromagnetic coil. The electrical solenoid is adapted to operatively generate reciprocating mechanical movement of the reciprocating piston when the electromagnetic coil is energized by the electrical power source. The reciprocating piston is coupled to the string hook and adapted to operatively pivot the string hook and thereby discharge a bow string therefrom. A trigger is adapted to operatively selectively connect the electrical power source with the electromagnetic coil. The reciprocating piston has a roller on a first end most nearly adjacent to the string hook, and distal to the reciprocating piston first end, a shoe bottom is adapted to engage with the housing to limit travel of the reciprocating piston towards the solenoid electromagnetic coil.
In a third manifestation, the invention is a method of releasing a bow string. The method includes the steps of: detecting a trigger pull representative of an intent to release the bow string; determining a firing option from the group of fire on trigger pull, fire on trigger release, and random delay; and energizing an electro-magnetic actuator operative to trigger bow string release after a time interval subsequent to trigger pull detection, the time interval adjusted based upon the firing option determination.
OBJECTS OF THE INVENTION
Exemplary embodiments of the present invention solve inadequacies of the prior art by providing a bow string release having a housing encasing a battery, circuit board, mechanical linkage, and a trigger to actuate the mechanical linkage. The mechanical linkage has a plurality of pivotal couplings that permit low-friction and smooth operation. The trigger and circuit board operatively energize an electro-mechanical device such as a solenoid, which produces linear motion. A roller terminating the solenoid engages a pivotal drive cam to convert the linear motion into rotary motion. Proper arrangement of the linkages ensures a slight over-center biasing of the linkages to securely and reliably hold a bow string, while also ensuring a minimal force to release the string. The present invention and the preferred and alternative embodiments have been developed with a number of objectives in mind. While not all of these objectives are found in every embodiment, these objectives nevertheless provide a sense of the general intent and the many possible benefits that are available from embodiments of the present invention.
A first object of the invention is to provide smooth, uniform, reliable, controlled and silent or very quiet string release. A second object of the invention is to provide a simple to use, easy to engage, auto-resetting, ambidextrous string release that provides both right and left-handed archers with the ability to hold a string in drawn position. Another object of the present invention is to enable an archer to hold a string without significant abrasion or disruption of circulation in the finger tips. A further object of the invention is to provide a bow string release having a release sensitivity independent of bow pull force, string characteristics and other similar variable parameters. Yet another object of the present invention is to provide an archer the option to select string release on trigger pull, string release on trigger release, or delayed string release to help reduce target panic. An additional object of the invention is to provide a small, rugged and reliable, light weight, easily carried upon a lanyard, and economical to manufacture bow string release.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, advantages, and novel features of the present invention can be understood and appreciated by reference to the following detailed description of the invention, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a preferred embodiment bow string release designed in accord with the teachings of the present invention from a projected view.
FIG. 2 illustrates the preferred embodiment bow string release of FIG. 1 with the top portion of the clamshell housing removed to reveal inner components, and with a select few other components removed, from a projected view similar to that of FIG. 1 .
FIG. 3 illustrates a first alternative embodiment bow string release similar to that of FIG. 2 from top view and with the top portion of the clamshell housing removed, and with a select few other components removed.
FIG. 4 illustrates the first alternative embodiment bow string release of FIG. 3 from a rear projected and enlarged view.
FIG. 5 illustrates the first alternative embodiment bow string release of FIG. 3 from an enlarged top view, showing only the string hook, follower link, drive cam, and pivots there between.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In a preferred embodiment of the invention illustrated in FIGS. 1 and 2 , and with particular reference to FIG. 1 , a bow string release 1 is comprised of a housing 10 that may be readily manually grasped, such as the clamshell housing 10 illustrated therein, though any suitable housing may be provided. The top and bottom portions of clamshell housing 10 are secured to each other using a plurality of socket head cap screws 18 , though any suitable fasteners, including permanent fasteners and adhesives, may be used.
A trigger 30 may be provided at any suitable location, though in the preferred embodiment, trigger 30 is located at a position that will be conveniently actuated by a thumb or finger. A string hook 52 will engage the bow string, while a drive cam 54 and follower link 58 will move string hook 52 from a string-retaining position as shown in the drawing figures to a string-release position and back again. Trigger 30 , which may be of any geometry or structure, is used by an archer to selectively control the movement of string hook 52 . Consequently, any apparatus that detects an intent by an archer to release the string will be understood herein to be a trigger in accord with the teachings of the present invention.
A lanyard connection 12 or the like is preferred. As will be understood, a bow string release such as illustrated herein may be accidentally dropped. While it may be possible to construct all of the components sufficiently to withstand a drop onto a hard surface, a lanyard will be much less expensive and generally very convenient for most archers. A lanyard connection 12 may be provided at any suitable location, and in the preferred embodiment is located at an end of bow string release 1 distal to string hook 52 .
A battery cap 16 will preferably provide closure about and access to a battery compartment 14 visible in FIG. 2 . FIG. 2 illustrates bow string release 1 with one side of clamshell housing 10 removed, but with battery cap 16 still in place. Within battery compartment 14 are a pair of battery connectors 15 that allow relatively simple battery connection and disconnection. In the preferred embodiment of FIGS. 1 and 2 , a relatively large battery 20 is provided, though it will be understood that any suitable source of electrical energy may be used. Battery 20 may be easily accessed separately and independently from the remaining components by removal of battery cap 16 , though there is no requirement that this be the case.
When a person operates trigger 30 , they will do so by pivoting trigger 30 about trigger pivot 32 , which in turn applies a compressive force to micro-switch actuator 36 . Sufficient trigger rotation will actuate micro-switch 34 , producing an indication that the archer would like to initiate a string release cycle. Trigger 30 will preferably not be attached loosely, and so may be securely coupled to micro-switch actuator 36 . A secure coupling might be a direct bonding or affixing of trigger 30 to micro-switch actuator 36 . In a first alternative, the range of rotation of trigger 30 may be set such that trigger 30 cannot rotate away from micro-switch actuator 36 . In a further alternative, there may be provided a relatively soft spring biasing trigger 30 towards micro-switch 34 . In the case of a soft spring, the bias spring must be of lower force than necessary to actuate micro-switch 34 .
Micro-switch 34 is mounted upon and electrically coupled to circuit board 40 provided in the preferred embodiment bow string release 1 . Circuit board 40 will preferably be populated with various electronic components that enable various electrical and electronic control functions to be implemented. These components may take many forms and configurations, as is known in the electrical arts, implemented as electronic hardware, software stored on a computer readable medium and executable by a processor, or combinations of both. The various functions described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a reduced instruction set computing processor (RISC), a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, micro-controller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints.
In the preferred embodiment, an archer may select when string hook 52 will release. This is preferably achieved through an interaction between trigger 30 , circuit board 40 , and mechanical linkage 50 . A first option is to trigger release of the string from string hook 52 when trigger 30 is pulled, which corresponds with the closing of micro-switch 34 . A second option is to trigger the release of the string from string hook 52 when trigger 30 is released subsequent to being pulled. Third and fourth options are to trigger the release of the string at some delayed time interval after either the pull or alternatively the release of trigger 30 . Yet another set of options include the triggering at random time intervals subsequent to the pull or release of trigger 30 . Where an archer is simply preserving their fingers, they may opt for immediate release of the string responsive to either the pull or release of trigger 30 , depending upon their personal preference. However, where target anxiety is a factor, a delay time interval or a random delay time interval may be preferred by the archer.
Electrical control of the release of the string from string hook 52 occurs through a combination of a source of electrical energy such as a battery 20 located within battery compartment 14 , electrical circuitry on circuit board 40 , and an electro-mechanical device such as solenoid 62 converting the electrical energy to mechanical motion. When electrically activated, solenoid 62 will drive solenoid piston 64 forward from the solenoid toward string hook 52 . The amount of time that solenoid 62 is energized is referred to as the dwell time. In the preferred embodiment, the dwell time is adjustably controlled by the electrical circuitry on circuit board 40 , and so may be set or adjusted to accommodate the needs of particular mechanical components, bow draw force, and any other factors that might affect how much dwell time is required. For exemplary purposes, and not solely limiting the present invention thereto, the dwell time may only be a few milliseconds as will be further explained herein below.
After solenoid 62 has been energized, solenoid piston 64 in turn pushes on drive cam 54 , and, as may be appreciated from FIG. 2 , drive cam 54 will rotate about drive cam fixed pivot 56 . Fixed pivot 56 is described as a fixed pintle owing to the actual anchoring or fixing into housing 10 . Drive cam 54 is coupled to follower link 58 through a floating pin 61 that permits rotation there between. Floating pin 61 is not anchored to housing 10 , and so is free to move or float relative thereto.
In the process of rotating, drive cam 54 will then move follower link 58 in an arc about drive cam fixed pivot 56 . This motion causes follower link 58 to pull on a floating pivot 60 that couples follower link 58 to string hook 52 , in turn causing string hook 52 to rotate about string hook fixed pivot 53 . This rotation of string hook 52 is what ultimately releases the bow string from string hook 52 . In this preferred embodiment, an arrow nocked on the bow string will be pulled and released generally in a direction parallel to the longitudinal axis of the preferred bow string release.
In the preferred embodiment, solenoid piston 64 is always in contact with drive cam 54 . However, the invention is not solely limited thereto. Instead, in an alternative embodiment a stop could, for exemplary purposes, be provided to limit the rotation of drive cam 54 . In this case, then the retraction of solenoid piston 64 , which can be initiated either by return spring 68 or by a return spring internal to solenoid 62 , can lead to the formation of a gap between piston roller 65 and solenoid piston 64 . A drawback of this alternative embodiment is the tendency for solenoid piston 64 to slap when driven into contact with drive cam 54 . However, slap can be mitigated through sound-dampening materials. The benefit of this alternative embodiment is the additional kinetic energy from the momentum of solenoid piston 64 that can generate a greater initial force upon drive cam 54 .
In the preferred embodiment, each of the four pintles, including string hook pivot 53 , drive cam fixed pivot 56 , and floating pivots 60 , 61 create a center of rotation, which in turn defines an axis of rotation. All four axes are preferably parallel to one another, which prevents interference and binding that might otherwise occur.
When a bow string 51 illustrated in FIG. 5 is pulled upon by string hook 52 , the force vector 70 of string 51 if unopposed would cause string hook 52 to rotate in a clockwise direction about string hook pivot 53 and release the string. However, with proper dimensioning, in the position illustrated in FIG. 3 floating linkages 60 , 61 and drive cam fixed pivot 56 are not quite in line. As best illustrated in FIG. 5 , there is a slight “V” shape. A plane 72 contains the rotational axes of pivots 56 , 60 . However, the axis of rotation 69 of floating pivot 61 is slightly offset from plane 72 in a direction closer to solenoid 62 . This means that force vector 70 generated upon string hook 52 by the pull upon bow string 51 will produce a force vector 71 tending floating pivot 60 towards drive cam fixed pivot 56 . Since drive cam fixed pivot 56 is fixed with respect to housing 10 , this generates an opposed force vector 73 . Any rotation of string hook 52 will then drive the axis of rotation 69 of pivot 61 to move closer to solenoid 62 , shifting in the direction of and with a force defined by force vector 74 . However, from FIGS. 2 and 3 , it will be apparent that in the string holding position of the figures, drive cam 54 is not free to rotate.
In the de-energized position shown in the figures, piston 62 is fully retracted. Since solenoid piston 64 is boot shaped, the bottom of the boot simply presses against features formed in housing 10 as best viewed in FIG. 2 . Since solenoid 62 is fully retracted and housing 10 prevents solenoid piston 64 from moving, solenoid piston 64 will generate an equal and opposite force vector to oppose force vector 74 . This creates a static and strong holding force, to securely hold the bow string 51 , even with extremely high draw forces. Consequently, as long as follower link 58 , drive cam 54 , solenoid piston 64 , and housing 10 are all sufficiently durable, then a bow string release designed in accord with the teachings of the invention can be used to draw against an enormous draw force. While a boot shape is illustrated for solenoid piston 64 , it will be understood that any geometry which will engage and stop at an appropriate feature in housing 10 is suitable. For exemplary purposes, and not solely limiting the invention thereto, a bell-shaped solenoid piston or other similar flared geometry would readily be substituted for boot shaped solenoid piston 64 .
As understood from the foregoing, there is no electrical energy or spring force required to hold string hook 52 in the string pull position illustrated in the Figures. As long as the angle between a first line segment from the center of pivot 56 to the center of pivot 61 is offset from parallel with a second line segment from the center of pivot 60 to the center of pivot 61 , and shifted so that the center of pivot 61 is slightly closer to solenoid 62 than a line from the center of pivot 56 to the center of pivot 60 , then the draw force alone will hold string hook 52 in place.
When solenoid 62 is fired, it must drive axis of rotation 69 across plane 72 and closer to bow string 51 . Once axis of rotation 69 crosses plane 72 , then string hook 52 may rotate in a clockwise direction, essentially unopposed, for a very rapid release. The only restriction on the speed of rotation is a low-force return spring 66 shown in FIG. 3 , and it is return spring 66 that will then automatically reset string hook 52 to the position of the Figures, once string 51 is released.
Consequently, solenoid 62 pushing piston roller 65 against drive cam roller face 57 must generate a force great enough to overcome force vector 74 . Noteworthy here is that the closer axis of rotation 69 is to plane 72 , the smaller force vector 74 will be. In other words, and again only for exemplary purposes, if axis of rotation 69 were exactly within plane 72 , then all of the force opposing string hook 53 rotation will come entirely from drive cam fixed pivot 56 through force vector 73 . Only in this exact case where axis of rotation 69 is exactly within plane 72 , then force vector 74 is zero, meaning there is no additional force pushing back against solenoid 62 . Even when axis of rotation 69 is close to plane 72 , then force vector 74 will be near zero. This is important, because the amount of force required of solenoid 62 to release the bow string 51 is primarily determined by the magnitude of force vector 74 . In other words, solenoid 62 can be much smaller and will draw less power if axis of rotation 69 can be kept close to plane 72 . In such case, then not only is less force required, but the amount of time that solenoid 62 needs energized, referred to herein above as dwell time, is also very small. The benefit of a smaller solenoid 62 is obvious in size, weight, and cost. Not only can solenoid 62 be smaller, but the shorter dwell time also allows battery 20 to be much smaller while still providing good battery life.
At the time of design of the bow string release, the precise length of follower link 58 and the exact dimensions of drive cam 54 and string hook 52 will be determined. Furthermore, the tolerances and any play within the floating pivots 60 , 61 and at the drive cam fixed pivot 56 and string hook pivot 53 will be determined. Those skilled in the arts of physics and engineering can then determine how much offset between axis of rotation 69 and plane 72 is required to ensure a safe and secure holding of bow string 51 . In other words, in the hypothetical example above where axis of rotation 69 is within plane 72 , a small jolt could lead to an accidental release. By providing a small force 74 , accidental releases are easily prevented. Then those same persons skilled in the art of physics and engineering can easily calculate the magnitude of this force 74 for a given force vector 70 , and so an appropriate solenoid 62 and battery 20 may be selected based upon the known dimensions and manufacturing tolerances.
With reasonably sturdy construction, there is no practical limit to the draw force that the invention may be used with. Instead, the limiting factor will normally be the force required to be generated by the solenoid to push axis of rotation 69 across plane 72 . In order to push axis of rotation 69 across plane 72 , there will be a slight counterclockwise rotation of string hook 52 just prior to string release.
As noted above, manufacturing tolerances will directly affect the strength of solenoid required. This is because the return spring will ideally lock string hook reliably and repeatedly into the position shown in the Figures. Any loose fittings or dimensional deviations will increase the amount that axis of rotation 69 must be shifted form plane 72 and still work reliably. As outlined above, the greater the shift of axis of rotation 69 from plane 72 , the more powerful a solenoid that is also required.
A significant feature of each of the embodiments of the present invention is that the string hook 52 self-resets. In other words, in the preferred and first alternative embodiment bow string releases 1 , 2 of FIGS. 1-4 , one or more additional return springs such as return spring 66 and solenoid piston return spring 68 may be provided, such as illustrated in FIG. 3 . This is necessary because solenoid piston 64 is not affixed to the remaining linkage, and instead uses piston roller 65 to provide smooth, substantially reduced friction connection between piston roller 65 and drive cam 54 . Return spring 66 is anchored at a first end to return spring fixed anchor pin 67 that is rigidly affixed into housing 10 . A second distal end of return spring 66 is coupled to return spring anchor pin 55 , which is rigidly affixed into drive cam 54 . The arrangement of drive cam 54 , drive cam roller face 57 , anchor pin 55 , solenoid piston 64 , piston roller 65 , and fixed anchor pin 67 is best illustrated in FIG. 4 , which has been illustrated without return springs 66 and 68 to enable better viewing. Piston roller 65 rolls against the slightly curved drive cam roller face 57 , while a slot adjacent thereto in drive cam 54 enables return spring 66 to engage with anchor pin 55 .
In one alternative embodiment, solenoid piston 64 may be coupled through a floating pivot such as a pin or the like to drive cam 54 . In this alternative embodiment, a return spring which is commonly a part of an electrical solenoid will pull the solenoid piston 64 back into solenoid 62 when solenoid 62 is de-energized. Return of solenoid piston 64 will reset string hook 52 to the position such as illustrated in FIG. 1 , ready to be easily hooked onto a bow string and used again to draw and release the bow string.
Solenoid piston 64 may be constructed as a single integral component, typically having a cylindrical portion within the body of solenoid 62 , or may be fabricated from several discrete components that are coupled together, such as in the embodiments of FIGS. 1-4 . One or more piston guide pins 63 may be provided, and if so, corresponding slots are formed in solenoid piston 64 to permit solenoid piston 64 to reciprocate towards and away from drive cam 54 .
String hook 52 rotates about string hook pivot 53 , and when moving from the string retaining position of FIG. 3 , will rotate in a clockwise direction about string hook pivot 53 to release an archery string. Bow string release 2 illustrated in FIGS. 3 and 4 is similar to bow string release 1 of FIGS. 1 and 2 , and has a similar micro-switch 34 , trigger pivot 32 , circuit board 40 , solenoid 62 , solenoid piston 64 , drive cam 54 , follower link 58 , and string hook 52 . The battery 20 and housing 10 have been changed slightly, and trigger 30 is not separately illustrated. However, the string travel vector, which corresponds to the arrow travel, matches force vector 70 of FIG. 5 and is approximately in line with the longitudinal axis of first alternative embodiment bow string release 2 , and operation is very similar to that of preferred embodiment bow string release 1 . Nevertheless, other variants are also contemplated herein, such as a string travel vector and associated arrow travel perpendicular to the longitudinal axis of the bow string release.
From the foregoing figures and description, several additional features and options become more apparent. First of all, a bow string release designed in accord with the teachings of the present invention may be manufactured from a variety of materials, including metals, resins and plastics, ceramics or cementitious materials, or even combinations, laminates or composites of the above. The specific material used may vary as will be determined by a designer at design time. In addition, where electrical components are illustrated and preferred, it is further contemplated herein that mechanical components may be substituted therefor. One such component that is contemplated herein is the solenoid, which is contemplated as being replaced with a mechanical energy storage device, such as a spring and sear that permits a plunger to be manually drawn back and then held in place by the sear. Upon release of the sear, the plunger may then be propelled forward by the energy stored in the spring, to drive the cams and follower links, to in turn pivot the string hook about. Likewise, while a single string hook is illustrated and preferred, which permits rapid attachment to a bow string simply by hooking the string, other apparatus may be substituted therefor, such as a set of scissors-motion jaws or other apparatus.
While the foregoing details what is felt to be the preferred embodiment of the invention, no material limitations to the scope of the claimed invention are intended. Further, features and design alternatives that would be obvious to one of ordinary skill in the art are considered to be incorporated herein. The scope of the invention is set forth and particularly described in the claims herein below. | A bow string release has a housing encasing a battery, circuit board, mechanical linkage, and a trigger to actuate the mechanical linkage. The trigger and circuit board operatively energize an electro-mechanical device such as a solenoid, which produces linear motion. A roller terminating the solenoid engages a pivotal drive cam to convert the linear motion into rotary motion. A follower link couples the pivotal drive cam to a string hook. Proper arrangement of the linkages ensures a slight over-center biasing of the linkages to securely hold a bow string, while also ensuring that only a minimal force generated by the solenoid will be required to release the string. | 5 |
FIELD OF THE INVENTION
The present invention is directed to a device for warming fuel before it is combusted inside a vehicle engine.
BACKGROUND OF THE INVENTION
Numerous types of fuel warming systems for vehicles are currently in use. Fuel warming systems warm fuel before it is injected into the engine. The warming of fuel may help the efficiency of the combustion inside the engine. The present invention features an improved fuel warming device, which may be used, with unleaded fuel or diesel fuel.
Any feature or combination of features described herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this specification, and the knowledge of one of ordinary skill in the art. Additional advantages and aspects of the present invention are apparent in the following detailed description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the fuel warming device of the present invention.
FIG. 2 is a side view of the fuel warming device of FIG. 1 .
FIG. 3 is a side cross sectional view of the fuel warming device of FIG. 1 .
FIG. 4 is a side view of the fuel warming device of FIG. 1 as installed in a vehicle.
FIG. 5 is a perspective view of a control switch of the fuel warming device of the present invention as mounted on a dash of the vehicle.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIGS. 1-5 , the present invention features a fuel warming device 100 for increasing the temperature of fuel for an engine 430 of a vehicle 410 for improved combustion within the cylinders of the engine 430 . The fuel warming device 100 can be used with diesel fuel or unleaded fuel.
The fuel warming device 100 comprises a generally cylindrical housing 110 (e.g., generally cylindrical housing) for heating the fuel. The housing 110 has a first end 111 , a second end 112 , an inner surface 113 , and an outer surface 114 , which altogether enclose an inner compartment 115 . The housing 110 can be installed in a vehicle 410 , for example near the engine 430 of the vehicle 410 (see FIG. 4 ). In some embodiments, the housing 110 is constructed from a material comprising a metal, e.g., copper, the like, or a combination thereof.
Referring now to FIG. 3 , a copper coil tube 210 having a first end 211 and a second end 212 spans the length of the housing 110 (e.g., as measured from the first end 111 to the second end 112 ) in the inner compartment 115 of the housing 110 . The first end 211 of the copper coil tube 210 extends outwardly through the first end 111 of the housing 110 and the second end 212 of the copper coil tube 210 extends outwardly through the second end 112 of the housing 110 . Fuel from a fuel line 440 can enter the copper coil tube 210 via the first end 211 , and fuel can exit the copper coil tube 210 via the second end 212 . Fuel exiting the copper coil tube 210 is subsequently injected into the engine 430 of the vehicle 410 .
A heating fluid 230 is disposed in the inner compartment 115 of the housing 110 . The heating fluid 230 fills the inner compartment 115 of the housing 110 and surrounds the copper coil tube 210 . In some embodiments, the heating fluid 230 comprises a material such as an anti-freeze, a thermal transfer oil, the like, or a combination thereof. Such heating fluids are well known to one of ordinary skill in the art. The heating fluid 230 helps transfer heat quickly and evenly distributes the heat in the inner compartment 115 of the housing 110 . The heating fluid 230 helps to held heat in the housing 110 (heat is held longer in the housing 110 with the heating fluid 230 than without the heating fluid 230 ).
A heating element 250 is disposed in the inner compartment 115 of the housing 110 . The heating element 250 is for increasing the temperature of the heating fluid 230 that surrounds the copper coil tube 210 . When the heating element 250 is activated, the temperature of the heating fluid 230 increases, which warms the copper coil tube 210 . Fuel that runs through the copper coil tube 210 is then warmed by the copper coil tube 210 , in some embodiments, the heating element 230 is a 12-volt submersible heater. In some embodiments, the heating element 250 is disposed in the center portion of the coil 210 , in some embodiments, the heating element 250 is spread throughout portions of the inner compartment 115 of the housing 110 .
The heating element 250 is operatively/electrically connected to an electrical connection component 280 . In some embodiments, the electrical connection component 280 is disposed on the second end 112 of the housing 110 . The electrical connection component 280 is for operatively connecting the heating element 250 to a power source, for example the battery or fuses 450 of the vehicle 410 . In some embodiments, one or more electrical wires 290 connect the electrical connection component 280 to the battery or fuses 450 of the vehicle 410 .
In some embodiments, the fuel warming device 100 of the present invention further comprises an electrical housing 600 . In some embodiments, the electrical housing 600 is disposed on the outside surface 114 of the housing 110 . In some embodiments, a power switch 610 is disposed on the electrical housing 600 , which allow a user to turn the fuel warming device 100 on and off. For example, in some embodiments, the heating element 250 is operatively/electrically connected to the power switch 610 of the electrical housing 600 . The power switch 610 can move between an on position (to turn on the heating element 250 ) and an off position (to turn off the heating element 250 ), for example.
In some embodiments, the fuel warming device 100 further comprises a power indicator light 620 for indicating when the fuel warming device 100 (e.g., heating element 250 ) is on. For example, the power indicator light may be operatively connected to the power switch 610 . When the power switch is in the on position, the indicator light 620 may be illuminated. When the power switch is in the off position, the indicator light 620 may not be illuminated. Alternatively, the indicator lights may function via different colors or light patterns when the device is on or off.
In some embodiments, the electrical housing 600 comprises one or more precautionary fuses 670 . Precautionary fuses are well known to one of ordinary skill in the art and are known to function to help prevent power overloads.
Referring now to FIG. 1 , in some embodiments, a wire conduit 680 operatively connects the electrical connection component 280 to the electrical housing 600 (e.g., the indicator light 620 , the power switch 610 , and/or fuses 670 ).
In some embodiments, the fuel warming device 100 further comprises a thermal disc. In some embodiments, the thermal disc is similar to a thermostat, for example the thermal disc measures the temperature of the fuel and/or the heating fluid 230 . The thermal disc may shut off the fuel warming device 100 (e.g., the heating element 250 ) off if a particular temperature has been reached. Or, in some embodiments, the thermal disc may turn on the fuel warming device 100 (e.g., the heating element 250 ) if the thermal disc detects that the fuel is too cold. In some embodiments, the thermal disc may help prevent the heating fluid 230 and/or fuel from overheating. The thermal disc may help to conserve energy, for example the device 100 is turned off automatically when it is not needed.
In some embodiments, the fuel warming device 100 further comprises a remote control switch device 520 for allowing a user to turn the fuel warming device 100 on and off from inside the vehicle 410 . In some embodiments, the control switch device is installed inside the vehicle 410 , for example on the dash 460 of the vehicle 410 . In some embodiments, the fuel warming device 100 may be activated at any time by the user so that fuel is delivered to the engine 430 at a predetermined temperature. In some embodiments, the fuel warming device 100 can be hooked up to an ignition system of the vehicle for easy activation. The remote control switch device 520 may be operatively connected to the electrical connection component 280 .
Without wishing to limit the present invention to any theory or mechanism, it is believed that the fuel warming device 100 of the present invention is advantageous because it will help to ensure optimum power and performance from the fuel being burned, thereby improving fuel economy for the vehicle 410 . The fuel warming device 100 is designed such that the inner compartment 115 of the housing 110 is full of heating fluid 230 and constantly heats the coil 210 (when turned on). This design helps to keep the temperature of the heating fluid 230 and/or fuel constant, and helps prevent the device from freezing.
In some embodiments, the fuel warming device 100 is mounted within the engine compartment of the vehicle 410 . In some embodiments, the fuel is warmed in about 6 to 7 minutes.
In some embodiments, the warming device 100 is installed in an aftermarket vehicle. In some embodiments, the warming device 100 is installed in a vehicle during production.
In some embodiments, the fuel warming device 100 further comprises insulation 119 . The insulation 119 may be disposed, for example, between the outside surface 114 and the inside surface 113 of the housing 110 (see FIG. 3 ).
The fuel warming device 100 may be constructed in a variety of sizes. In some embodiments, the housing 110 is about 12 inches in length as measured from the first end 111 to the second end 112 . In some embodiments, the housing 110 is between about 6 to 12 inches in length as measured from the first end 111 to the second end 112 . In some embodiments, the housing 110 is between about 12 to 16 inches in length as measured from the first end 111 to the second end 112 . In some embodiments, the housing is more than about 16 inches in length.
In some embodiments, the housing 110 is about 4 inches in diameter. In some embodiments, the housing 110 is between about 2 to 4 inches in diameter. In some embodiments, the housing 110 is between about 4 to 6 inches in diameter. In some embodiments, the housing 110 is more than about 6 inches in diameter.
In some embodiments, the electrical housing 600 comprises an optional pressure gauge for testing purposes, for example for testing when the fuel warming device 100 is being constructed.
As used herein, the term “about” refers to plus or minus 10% of the referenced number. For example, an embodiment wherein the housing 110 is about 5 inches in diameter includes a housing 110 that is between 4.5 and 5.5 inches in diameter.
The disclosures of the following U.S. patents are incorporated in their entirety by reference herein: U.S. Pat. No. 4,700,047; U.S. Pat. No. 5,159,915; U.S. Pat. No. 5,378,358; U.S. Pat. No. 6,845,739; U.S. Pat. No. 6,743,356; U.S. Pat. No. 6,179,577; U.S. Pat. No. 4,865,005; U.S. Pat. No. 4,612,897.
Various modifications of the invention, in addition to those described herein, will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims. Each reference cited in the present application is incorporated herein by reference in its entirety.
Although there has been shown and described the preferred embodiment of the present invention, it will be readily apparent to those skilled in the art that modifications may be made thereto which do not exceed the scope of the appended claims. Therefore, the scope of the invention is only to be limited by the following claims. | A fuel warming device for increasing the temperature of a vehicle's fuel from the fuel line before entering the engine featuring a housing, a copper coil spanning the housing, a heating fluid filling the housing, and a heating element for heating the heating fluid operatively connected to a power source via an electrical connection component. The fuel from the fuel line is heated in the copper coil tube by the heated heating fluid. | 8 |
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